Absorbent structure

ABSTRACT

The present invention relates to an absorbent structure, preferably for use in absorbent products, such as used in the food, consumer, household, building and construction, beauty and medical industry, and as used in the personal hygiene industry. The substantially cellulose free absorbent structures continuously immobilise absorbent polymer material via initial smaller pockets and subsequently larger compartments allowing excellent fluid management of the absorbent polymer material in dry, partially and fully liquid loaded state. Preferably such absorbent structure volume increases are result of temporary secondary attachment patterns made in combination with substantially permanent primary attachment grids allowing the release of bigger volumes from the initial smaller volumes by detachment of the secondary attachments. Furthermore the absorbent structure according to an embodiment of the invention non-homogeneously swells to form a liquid-managing surface structure as a result of exposing the absorbent structure to liquid. The present invention foresees in the need for improved flexible, thin, lightweight absorbent structures which overcome the absorbency problems of the prior art during absorption, distribution and retention of liquids with optimal fit.

FIELD OF THE INVENTION

The present invention relates to an absorbent structure having a highconcentration of absorbent polymer material within an integrated fluidmanagement system, preferably for use in an absorbent product, such asfor example used in the food industry (e.g. coffee pads), the consumerindustry (e.g. disposable body warmers), the household industry (e.g.sheet formed detergent articles), building and construction (e.g. filtermaterials and insulation), beauty and medical industry (e.g. make-uppads, anti-septic wads) and absorbent articles as used in the personalhygiene industry (e.g. feminine hygiene garments, baby diapers andpants, adult incontinence garments). The present invention also relatesto an absorbent article comprising such absorbent structure and to amethod and apparatus for manufacturing such absorbent structure.

BACKGROUND OF THE INVENTION

Disposable absorbent articles have an absorbent structure for absorbingbodily exudates, a soft liquid-permeable top sheet on the wearer sideand a liquid-impermeable back sheet on the garment side. The absorbentstructure in between is normally made from a mixture of cellulose fibersor other fibrous substance and an absorbent polymer material. Thesefibrous substances make these absorbent articles typically quite fluffyand bulky.

In recent years there has been increasing demand for flexible, thinner,lightweight absorbent structures to resolve various problems ofmanufacturing, marketing, design, fit, wearing comfort, distribution,garbage disposal, material and energy consumption, transportation andstorage costs and the like.

The most common method currently used to meet these demands indisposable absorbent articles is to reduce the amount of cellulose fibreor other support material within and surrounding the absorbent structureand/or use larger amounts of absorbent polymer materials. Consequentlysuch absorbent articles have a smaller proportion of hydrophiliccellulose fibres and/or a higher proportion of absorbent polymersmaterials. Some of these absorbent articles may be better at storingliquid, however they are not necessarily good at absorbing anddistributing liquid when the absorbent article is actually being used.It will thus be apparent from the above that the absolute and relativeproportions of the fibrous material and absorbent polymer material areclosely linked in light of article performance. Hence there are limitson reducing the amount of hydrophilic cellulose fibre and reducing thethickness of absorbent cores.

Many attempts have been undertaken to manufacture flexible, thin,lightweight absorbent structures, consisting of a high amount ofabsorbent polymer material. In order to obtain good absorbency,distribution and retention within such absorbent structures it has foundto be important to at least partially immobilize the absorbent material.Failing to provide sufficient structural integrity results in loss offunctional performance characteristics such as coherence, absorption,distribution and/or retention and results in failures related but notlimited to for instance leakages, high rewet values, etc. On the otherhand however the presence of this physical and/or chemical interactionin between the absorbent material and the restraining material oftenalso leads to a reduced absorption, distribution and/or retentionperformance. This is especially the case when such flexible, thin,lightweight absorbent structures, consisting of an absorbent polymermaterial are placed in between multiple enveloping layers.

The larger proportion of absorbent polymer materials and relatedimmobilisation requirements in substantially cellulose free absorbentarticles may thus greatly inhibit the absorption, distribution and/orretention of liquids if inadequately managed. It will be clear that theabsolute and relative proportions of the hydrophilic cellulose fibresand absorbent polymer materials need to be tightly controlled in orderto maintain the absorbent properties of the absorbent structures.Certainly decreased absorption speed and fluid distribution are commoncauses of failure. Since such hygienic absorbent articles are generallyalso disposable and need in some instances to be worn over many hoursthey require performance in a dry state as well as in a partially andfully bodily exudates loaded state.

The ability and capacity of an absorbent polymer material to absorb,distribute and retain liquid is dependent upon the form, position and/ormanner in which the absorbent polymer material is incorporated into theabsorbent structure. Since many absorbent structures have a relativelyhomogeneous and continuous distribution of absorbent polymer material,and thus exhibit a substantial homogeneous swelling, for second, thirdand next liquid insults such absorbent layers may actually act as aliquid barrier. This gel-blocking occurs when the absorbent polymermaterial located in regions of first contact starts to increase involume as a consequence of imbibing the fluid, thereby forming ahydro-gel. Gel blocking in and adjacent a zone of the absorbent layer ofinitial liquid contact prevents liquid from rapidly dispersing orwicking past the “blocking” material into the rest of the absorbentlayer and further liquid uptake by the absorbent layer must then takeplace via for instance a diffusion process that is much slower than therate at which liquid is applied to the absorbent layer. Especially whenabsorbent polymer material concentrations are absolutely or relativelyhigh and wetted, the hydro-gel can block the initial and/or additionalfluid from reaching other still more absorbent regions of the absorbentcore, thus leading to unappreciated, underused or unused absorbentcapacity. The diminished capacity results in leakages, well before theabsorbent core is fully saturated.

Gel-blocking is even increased in thin substantially cellulose freestructures where the liquid find little or limited macroscopic voidsand/or spaces which can be used for temporary, intermediate or finalliquid storage. Also the structural volume restrictions of theseabsorbent structures lead to a further reduced absorbent performance dueto limited swelling capacity of the absorbent polymer materialincreasing the tendency to functional failures and leakages. To remedy,absorbent article designers have and typically use additional side cuffsand acquisition layers which are expensive, inefficient and can onlypartly remedy these limitations. By not completely abandoning the use ofhydrophilic fibrous materials next to the use of absorbent polymermaterials this problem can be partially resolved, however, it will beclear that in such case the absolute and relative proportions ofabsorbent materials will unwillingly be restricted and thus anythickness reduction of the absorbent structure not fully optimised.

Multiple attempts have been made to provide the above flexible, thinner,light-weight absorbent articles comprising from low cellulose tosubstantially cellulose to completely cellulose free absorbentstructures combining absolute and/or relative high proportions absorbentpolymer material versus remaining absorbent materials: WO95/17868,hereby incorporated by reference, discloses an absorbent structurecomprising two fibre layers and an intermediate layer comprising anabsorbent polymer material in an amount exceeding 120 g/m² and particlesof a thermoplastic material. While this construction may provide goodimmobilisation of the absorbent polymer material in the dry state, itseems that only a lesser immobilisation can be achieved in the liquidloaded state. The thermoplastic material appears to stretch to a muchlesser extent than the potential swelling of the absorbent polymermaterials. Therefore, in particular when the absorbent structure is tobe used in an absorbent article to absorb and retain high amounts ofbodily exudates, for example a diaper or pants, the absorbent structuredisclosed herein may not be fully satisfactory. Furthermore the fibrousbulk material increases thickness and weight, reduces flexibility andraises the cost and environmental footprint of the absorbent structurewhich is highly unfavourable and undesirable.

WO95/26209, hereby incorporated by reference, describes an absorbentstructure having a region containing absorbent polymer material in highhomogenous and continuous quantities in the absence of any significantfibrous support material which however typically leads poor fluidmanagement. By poor fluid management it is meant that the regions ofabsorbent polymer material have insufficient integrity in dry, partiallywet and/or wetted state. This results in the physical continuity (andthus the capability of acquiring and transporting fluids throughinterstitial voids and capillaries) of the hydrogel formed upon swellingin the presence of fluids being substantially disrupted and altered,leading to the hydrogel layers being unintentionally separated, havinggaps being introduced, having areas that are significantly thinnedand/or broken up into a plurality of underperforming segments. Obviouslythis minimizing or completely negating coherence, permeability and flowconductivity properties of the absorbent structure results in highlyundesirable performance and unacceptable product failure.

EP1447066, hereby incorporated by reference, describes an absorbentstructure for the use in an absorbent article which aims to provide animproved immobilization of absorbent polymer material. An absorbentstructure is disclosed comprising a non-woven substrate layer, a layerof thermoplastic material in the form of a hot melt adhesive which bondsto the substrate layer to define a thermoplastic immobilizing web whichcaptures the absorbent polymer material. However, in order to adequatelysecure the absorbent material, one needs to use a significant amount ofthermoplastic material, which obviously leads to much higher costs andunappreciated stiffness and rigidity, thereby reducing good product fit,comfort and discreetness. Also, due to its internal cohesion, the layerof thermoplastic material exerts pressure and offers resistance againstthe free and complete swelling and take-up capacity and thus overallabsorption performance of the absorbent material. Furthermore the veryhigh quantities of thermoplastic material lead to physical and chemicalshielding of the absorbent polymer materials from the fluids, leading tounavoidable reduced absorption, distribution and retention performanceand importantly due to their single use put forward a significant burdenon society, industry and families from economic, environmental andsustainability view. Therefore, such absorbent structures are consideredto be unfavourable.

Whilst the above attempts describe various approaches to variousproblems, it is believed that none of these absorbent structures leadsto very favourable and performing absorbent structures or articles. Theinefficient use of the absorbent material capacity and complexmanufacturing processes makes neither of the above absorbent articleseconomically, technically and/or environmentally advantageous.

Hence, there is still an need in the art for an improved thin, flexible,lightweight absorbent structure with high concentrations of absorbentpolymer material which overcomes the problems of the prior art which isdiscreet, sustainable and/or relatively inexpensive taking in mindmanufacturing, marketing, design, fit, comfort, distribution, packaging,disposal, material, energy and transportation costs while preserving therequired fluid absorption, distribution, transport, coherence andretention properties. There is furthermore also a need for a method andapparatus to produce such absorbent structures at high production speedand low energy and raw material consumption.

SUMMARY OF THE INVENTION

As a result of exhaustive research to address the above-identified,derived and related problems, the inventor has found that substantiallycellulose free absorbent structures continuously immobilising absorbentpolymer material via initial smaller pockets (preferably more in amountcompared to later compartments) and subsequently larger compartments(preferably less in amount compared to initial pockets) allows excellentfluid management in relation to the available absorbent polymer materialin dry, partially and fully liquid loaded state. In a preferredembodiment according to the invention, the absorbent structuresaccording to the present invention allow excellent fluid management ofabsorbent polymer material by providing a plurality of initialsmaller-sized pockets adequately immobilizing dry absorbent polymerclusters thus avoiding unwanted migration and movement thereof in drystate, while during liquid uptake and expansion of the absorbent polymermaterials, the absorbent structure swells non-homogenously by graduallyunleashing and combining the pockets into fewer and bigger-sizedcompartments immobilizing the wet absorbent polymer materials therebyavoiding excess restraining or restriction in wet state; therebyadvantageously creating an internal fluid management as well as anexternal liquid management surface structure.

Such absorbent structure volume increases are preferably result oftemporary secondary attachment patterns made up for instance fromultrasonic bonds, preferably in combination with the substantiallypermanent primary attachment grids for instance also made up byultrasonic bonds, allowing the release of bigger volumes from theinitial smaller volumes by detachment of the secondary attachments. Inan alternative embodiment however these absorbent structure volumeincreases are the result of using flexible, extensible, elastic,stretchable and/or elastomeric materials such as for instance elasticnon-woven and/or breakable materials such as for instance semi-rigid,rigid and/or stiff paper or tissue respectively allowing additionalexpansion of and/or breaking up to larger volumes.

In a preferred embodiment the absorbent structure immobilizes, retainsand/or restrains the particulate material and the attachments seal, bondand/or join at least part of the outer layers together via ultrasonicbonding, thermo-bonding, pressure-bonding and/or glue-bonding means.These attachments preferably form and/or define pockets which cancontain particulate material, whereby the attachment regions compriseessentially and preferably no particulate material. Preferably theabsence of an excess or the complete elimination of syntheticimmobilisation admixtures (e.g. adhesive and binders, such asthermoplastic glues and webs) used for covering, restraining or bondingabsorbent polymers makes the structure technically, environmentally andeconomically very favourable. In an alternative embodiment however, thecomposite structure is covered with such thermoplastic materials, glues,binders and/or adhesives to fixate, pocket, encapsulate, bind and/orjoin these particulate material clusters to and/or in between one ormore layers. Additional materials and/or layers to provide extrafunctional and/or structural advantages such as strength, acquisition,absorption, distribution, transport, retention, etc. may also beincorporated.

In a preferred embodiment a substantially cellulose free absorbentstructure is provided comprising a carrier layer, an auxiliary layer andan absorbent polymer material there between, the carrier layer andauxiliary layer being at least partially joined together by attachmentsmade up of substantially permanent primary attachment grids and/orsubstantially temporary secondary attachment patterns, so as to form asandwich-like composite structure containing patterned absorbentparticulate polymer materials provided in at least some of theunattached regions between the carrier layer and auxiliary layer formingan absorbent polymer material area, the plurality of smaller-sizedpockets made up by at least substantially temporary secondaryattachments define spaces which immobilize the available dry volumeabsorbent polymer material, the substantially temporary secondaryattachment being gradually releasable as a result of exposing thesurrounding absorbent polymer material to liquid so as phase in anintermediate volume increase to fewer and medium-sized compartmentsimmobilising the partially wetted absorbent polymer material, andresulting in still fewer maximum-sized compartments immobilising thewetted absorbent polymer material to obtain continuous fluid management.

In a preferred embodiment a method for the manufacturing of an absorbentstructure is provided which comprises: providing a carrier layer,covering the carrier layer with an absorbent material, covering theabsorbent material with an auxiliary layer which is joinable to thecarrier layer; and in at least one position substantially temporaryand/or substantially permanently attaching the auxiliary layer to thecarrier layer, and by means of at least substantially temporarysecondary attachments defining small-sized pocket wherein dry absorbentmaterial is immobilized, such that by means of gradual release ofsubstantially temporary secondary attachment patterns bigger-sizedintermediate and final compartments are provided, thereby continuouslyimmobilising the absorbent material from dry to wetted state.

In a further aspect, the invention provides an absorbent articlecomprising an absorbent structure as provided by the invention. Inanother aspect the present invention provides a method and apparatus forthe manufacturing of such an absorbent structure.

As also described in EP priority application 10447020.8 and herebyincorporated by reference, an absorbent sandwich-like structure isprovided which comprises a distribution layer with an absorbent capacityand an immobilisation layer which joins to the distribution layer todefine compartments there between containing intermediate absorbentmaterial. In particular an absorbent structure for use in an absorbentarticle comprises a distribution layer having an absorbent capacity ofat least about 5 g/m², an immobilisation layer which is joined to thedistribution layer to define compartments there between, and anabsorbent material held in at least one of the compartments, whereinsaid absorbent material comprises an absorbent polymer material and fromzero to an amount less than about 40 weight percent absorbent fibrousmaterial, based on the weight of absorbent polymer material. Theabsorbent structure provides in particular an increased fluidcommunication structure including better adsorption and dispersion inand between the absorbent polymer material pockets, due to theadditional wicking and mass flow of liquids caused by the distributionlayer, limiting gel blocking, reducing rewet and minimizing leakages. Itfurther provides for a method and apparatus to produce such absorbentstructures at high production speed with low energy and raw materialconsumption.

As also described in EP priority application 10447021.6 and herebyincorporated by reference, an absorbent sandwich-like structure isprovided which comprises a substantially liquid-impermeable wickinglayer and an immobilisation layer which joins to the wicking layer todefine compartments there between containing intermediate absorbentmaterial. In particular an absorbent structure for use in an absorbentarticle comprises a substantially liquid-impermeable wicking layer, andan immobilisation layer which is joined to the substantiallyliquid-impermeable wicking layer to define compartments there between,and an absorbent material held in at least one of the compartments,wherein said absorbent material comprises an absorbent polymer material,and from zero to an amount less than about 40 weight percent absorbentfibrous material, based on the weight of absorbent polymer material. Thesubstantially liquid-impermeable wicking layer allows unbound liquidssuch as water, urine and/or other bodily exudates to more easily spreadout, which allows better distribution and transport so as to wet theside and lower sides of the absorbent polymer materials within thepockets. It ensure lower rewet values, less leakage risk and lesssurface wetness and thus increased reliability of the overall structure.It further provides for a method and apparatus to produce such absorbentstructures at high production speed with low energy and raw materialconsumption.

As also described in EP priority application 10447022.4 and herebyincorporated by reference, an absorbent sandwich-like structure isprovided which comprises a carrier layer, an auxiliary layer and anintermediate absorbent particulate material there between whereinsubstantially primary attachments and substantially secondaryattachments join the carrier layer and auxiliary layer together, wherebythe secondary attachments are loosened as a result of exposing theabsorbent structure to liquid whereas the primary attachments remainsubstantially intact. It further provides for a method and apparatus toproduce such absorbent structures at high production speed with lowenergy and raw material consumption.

As also described in EP priority application 10447023.2 and herebyincorporated by reference, an absorbent sandwich-like structure isprovided which comprises a carrier layer, an auxiliary layer and anintermediate absorbent material there between wherein substantiallypermanent primary attachments and substantially temporary secondaryattachments join the carrier layer and auxiliary layer together, wherebythe absorbent structure is made to in-homogeneously swell as a result ofexposing the absorbent structure to liquid to form a liquid-managingsurface structure. It further provides for a method and apparatus toproduce such absorbent structures at high production speed with lowenergy and raw material consumption.

As also described in EP priority application 10447024.0 and herebyincorporated by reference, a method and apparatus is provided forforming a sandwich-like structure, by depositing particulate material ina desired pattern onto a moving carrier layer. In particular a methodfor depositing particulate material in a desired pattern onto a movingcarrier layer is provided, which provides a clustering means withperforations corresponding to a desired pattern, driving the clusteringmeans in the same direction as and in close proximity to the movingcarrier layer, feeding a particle material stream from a particulatematerial supply means and directing the particle material stream throughthe clustering means onto the carrier layer. Preferably the particulatematerials are clustered via the inlet regions of the perforations andreleased via the outlet regions of the clustering means. The methodallows accurate forming of a pre-determined pattern of particulatematerial clusters at high production speed, with reduced raw materialusage and relative low cost. It furthermore provides the improved thin,flexible, lightweight particulate material absorbent structures withdiscretely deposited particulate material clusters thereon, complementedwith an auxiliary layer, such as for instance non-woven, tissue, paper,thermoplastic material and the like and/or affixed by attachment means,such as for instance glue, bonds, joints and the like, with particulatematerial clusters relatively immobilized there between so as to obtain asandwich structure usable in the form of an absorbent structure.

As also described in EP priority application 10447027 and herebyincorporated by reference, a method and apparatus is provided forforming a sandwich-like structure, by positioning particulate materialin a desired pattern onto a moving carrier layer. In particular a methodfor positioning particulate material in a desired pattern onto a movingcarrier layer is provided, providing a first material, an intermediatematerial and a second material, whereby prior to joining the firstmaterial to the second material, the distribution of the intermediateparticulate material is altered through an airflow. In a preferredembodiment the intermediate particulate material is providedsubstantially homogeneously on the first material prior to applying thepositioning airflow. When the intermediate material is undesirable inthe attachment area, the method describes the use of airflows, resultingfrom blowing and/or suction holes to evacuate the intermediate materialfrom the attachment area prior to or during bonding, leading to improvedand controllable attachment properties, thus increasing attachmentquality and utilisation of energy or materials. It furthermore providesimproved thin, flexible, lightweight absorbent particulate structures.

The product, method and apparatus according to preferred embodiments ofthe invention lead to highly appreciated thin, flexible and/orlight-weight absorbent structures which are economically,environmentally, technically and/or commercially advantageous, not inthe least since they are obtained without the need for substantial andbulky amounts of fibrous absorbent materials such as fluff and wood pulp(allowing “fluffless” advertisement claims) and are not usingsubstantial and expensive amounts of glue, binder, adhesive and/or otherthermoplastic materials (allowing “glueless” advertisement claims). Thisis unprecedented within the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 A-D provides cross-sectional schematic illustrations of absorbentstructures according to embodiments of the invention.

FIG. 2 provides a top view schematic illustration of an absorbentstructure according to an embodiment of the invention.

FIG. 3 provides a top view schematic illustration of an absorbentstructure in a partially wetted state according to an embodiment of theinvention, indicating substantial permanent primary attachments; and thegradual release by the still joined and already loosened temporarysecondary attachments.

FIG. 4 provides a top view schematic illustration of differently locatedand sized clusters of absorbent material according to an embodiment ofthe invention.

FIG. 5 provides top view schematic illustrations of an absorbentstructure according to an embodiment of the invention indicatingdifferent cluster patterns.

FIG. 6 A-B provides top view schematic illustrations of absorbentstructures according to an embodiment of the invention in intact (A) enloosened (B) state.

FIG. 7 provides a top view schematic illustration of an absorbentstructure according to an embodiment of the present invention,illustrating a built-in phased expansion by primary attachment grids andsecondary attachment patterns.

FIG. 8 provides a cross-sectional schematic illustration of a dryabsorbent structure having phased expansion according to an embodimentof the invention.

FIG. 9 provides a cross-sectional schematic illustration of a wettedabsorbent structure having phased expansion according to an embodimentof the invention.

FIG. 10 A-B provides a top view schematic illustration of absorbentstructures according to the invention, in dry state with a plurality ofsmaller-sized pockets (A) and in wet state with fewer and larger-sizedcompartments (B).

FIG. 11 provides a schematic process for manufacturing absorbentstructures according to the invention.

FIG. 12 is a top plan view of a diaper as a preferred embodiment of anabsorbent structure according to the invention, with the upper layerspartially cut away.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to an absorbent structure for use inabsorbent products, such as coffee pads, disposable body warmers, sheetformed detergent articles, filter material, insulation material, make-uppads, anti-septic wads, and preferably absorbent articles from thepersonal hygiene industry such as but not limited to feminine hygienegarments, baby diapers and pants, adult incontinence garments, variousabsorbent holders, liners, towels, inserts and the like; and to a methodand manufacturing of the same.

Unless otherwise defined, all terms used in disclosing the invention,including technical and scientific terms, have the meaning as commonlyunderstood by one of ordinary skill in the art to which this inventionbelongs. By means of further guidance, term definitions are included tobetter appreciate the teaching of the present invention.

As used herein, the following terms have the following meanings:

“A”, “an”, and “the” as used herein refers to both singular and pluralreferents unless the context clearly dictates otherwise. By way ofexample, “a compartment” refers to one or more than one compartment.

“About” as used herein referring to a measurable value such as aparameter, an amount, a temporal duration, and the like, is meant toencompass variations of +/−20% or less, preferably +/−10% or less, morepreferably +/−5% or less, even more preferably +/−1% or less, and stillmore preferably +/−0.1% or less of and from the specified value, insofarsuch variations are appropriate to perform in the disclosed invention.However, it is to be understood that the value to which the modifier“about” refers is itself also specifically disclosed.

“Absorbent article”, “absorbent garment”, “absorbing article”,“absorbing garment”, and the like as used herein are usedinterchangeably and refer to devices that absorb and contain bodilyexudates, and more specifically, refers to devices that are placedagainst or in proximity to the body of the wearer to absorb and containthe various liquids discharged from the body. Absorbent articles includebut are not limited to feminine hygiene garments, baby diapers andpants, adult incontinence garments, various diaper and pants holders,liners, towels, absorbent inserts and the like.

“Absorbent core” as used herein refers to a three-dimensional part ofthe absorbent structure, comprising liquid-absorbing material, useful toabsorb and/or retain bodily exudates.

“Absorbent component” as used herein refers to a structural constituentof an absorbent structure, e.g., a piece of an absorbent core, such asone of multiple pieces in a multi-piece absorbent core.

“Absorbent element” as used herein refers to a part of a functionalconstituent of an absorbent structure, e.g., a liquid acquisition layer,a liquid distribution layer, or a liquid storage layer formed of amaterial or materials having particular liquid handling characteristicssuitable for the specific function.

“Absorbent insert” as used herein refers to a device adapted forinsertion into an absorbent article and to serve as an absorbentstructure when so inserted.

“Absorbent layer” as used herein refers to a term referring to adiscrete, identifiable sheet-like or web-like element of an absorbentstructure which may remain detached and relatively movable with respectto another such element or may be attached or joined so as to remainpermanently associated with another such element. Each absorbent layermay itself include a laminate or combination of several layers, sheetsand/or webs of similar or diverse compositions.

“Absorbent polymer material”, “absorbent gelling material”, “AGM”,“superabsorbent”, “superabsorbent material”, “superabsorbent polymer”,“SAP” and the like as used herein are used interchangeably and refer toany suitable particulate (e.g., flaked, particulate, granular, orpowdered) or fibrous cross linked polymeric materials that can absorb atleast 5 times and preferably at least about 10 times or more its weightof an aqueous 0.9% saline solution as measured using the CentrifugeRetention Capacity test (EDANA 441.2-01).

“Absorbent polymer material area” as used herein refers to the area ofthe absorbent structure wherein adjacent layers are separated by amultiplicity of absorbent polymer material. Incidental contact areasbetween these adjacent layers within the absorbent particulate polymermaterial area may be intentional (e.g bond area's) or unintentional(e.g. manufacturing artefacts).

“Absorbent particulate polymer material” as used herein refers to anabsorbent polymer material which is in particulate form such as powders,granules, flakes and the like so as to be flowable in the dry state.

“Absorbent structure” as used herein refers to those elements of anabsorbent article comprising material or a combination of materialssuitable to absorb, distribute and retain bodily exudates.

“Absorption” as used herein refers to the process by which a liquid istaken up within a material.

“Acquisition layer”, “acquisition region”, “acquisition surface” or“acquisition material” and the like as used herein refer to a layerhaving a faster liquid uptake capability.

“Absorbency” is the ability of a material to take up fluids by variousmeans including capillary, osmotic, solvent, chemical or other action.

“Adult incontinence garment” as used herein refers to absorbent articlesintended to be worn by incontinent adults, for absorbing and containingbodily exudates.

“Adhesion” as used herein refers to the force that holds differentmaterials together at their interface.

“Adhesive” as used herein refers to a material, which may or may not beflowable in solution or when heated, that is used to bond materialstogether.

“Adsorption” as used herein refers to the process by which a liquid istaken up by the surface of a material.

“Airlaying” as used herein refers to forming a web by dispersing fibresor particles in an air stream and condensing them from the air streamonto a moving screen by means of a pressure or vacuum; a web of fibresproduced by airlaying is herein referred to an “airlaid”; an airlaid webbonded by one or more techniques to provide fabric integrity is hereinreferred to an “airlaid nonwoven”.

“Apparent density” as used herein refers to the basis weight of thesample divided by the calliper with appropriate unit conversionsincorporated therein. Apparent density used herein has the unit g/cm³.

“Attach”, “attached” and “attachment” as used herein are synonymous withtheir counterparts of the terms “fasten”, “affix”, “secure”, “bind”,“join” and “link”.

“Baby diaper” as used herein refers to absorbent articles intended to beworn by children, for absorbing and containing bodily exudates which theuser draws up between the legs and fastens about the waist of thewearer.

“Baby pants” as used herein refers to absorbent articles marketed foruse in transitioning children from diapers to underwear intended tocover the lower torso of children, so as to absorb and contain bodyexudates which article is generally configured like a panty garment andmanufactured with a completed waist encircling portion, therebyeliminating the need for the user to fasten the article about the waistof the wearer.

“Back region” as used herein refers to the portion of an absorbentarticle or part thereof that is intended to be positioned proximate theback of a wearer.

“Backing” as used herein refers to a web or other material that supportsand reinforces the back of a product.

“Basis weight” is the weight per unit area of a sample reported in gramsper square meter, g/m² or gsm.

“Bodily exudates”, “body exudates”, “bodily fluids”, “body fluids”,“bodily discharges”, “body discharges”, “liquids” and the like as usedherein are used interchangeably and refer to, but are not limited tourine, blood, vaginal discharges, breast milk, sweats and faecal matter.

“Binder”, “adhesive”, “glue”, “resins”, “plastics” and the like as usedherein are used interchangeably and refer to substances, generally in asolid form (e.g. powder, film, fibre) or as a foam, or in a liquid form(e.g. emulsion, dispersion, solution) used for example by way ofimpregnation, spraying, printing, foam application and the like used forattaching or bonding functional and/or structural components, elementsand materials, for example including heat and/or pressure sensitiveadhesives, hot-melts, heat activated adhesives, thermoplastic materials,chemical activated adhesives/solvents, curable materials and the like.

“Bond strength” as used herein refers to the amount of adhesion betweenbonded surfaces. It is a measure of the stress required to separate alayer of material from the base to which it is bonded.

“Capillary action”, “capillarity”, or “capillary motion” and the like asused herein are used to refer to the phenomena of the flow of liquidthrough porous media.

“Chassis” as used herein refers to a foundational constituent of anabsorbent article upon which the remainder of the structure of thearticle is built up or overlaid, e.g., in a diaper, the structuralelements that give the diaper the form of briefs or pants whenconfigured for wearing, such as a backsheet, a topsheet, or acombination.

“Cellulose fibres” as used herein refers to naturally occurring fibresbased on cellulose, such as, for example cotton, linen, etc.; wood pulpfibres are one example of cellulose fibres; man-made fibres derived fromcellulose, such as regenerated cellulose (rayon), or partially or fullyacetylated cellulose derivatives (e.g. cellulose acetate or triacetate)are also considered as cellulose fibres.

“Cluster” or the like as used herein refers to an agglomeration ofparticles and/or fibres.

“Chemically stiffened fibres”, chemically modified fibres”, “chemicallycross-linked fibres”, “curly fibres” and the like as used herein areused interchangeably and refer to any fibres which have been stiffenedby chemical means to increase stiffness of the fibres under both dry andaqueous conditions, for example by way of addition of chemicalstiffening agents (e.g. by coating, impregnating, etc.), altering thechemical structure of the fibres themselves (e.g. by cross-linkingchains, etc.) and the like.

“Cohesion” as used herein refers to the resistance of similar materialsto be separated from each other.

“Comprise,” “comprising,” and “comprises” and “comprised of” as usedherein are synonymous with “include”, “including”, “includes” or“contain”, “containing”, “contains” and are inclusive or open-endedterms that specify the presence of what follows e.g. a component and donot exclude or preclude the presence of additional, non-recitedcomponents, features, elements, members, steps, known in the art ordisclosed therein.

“Coverstock” as used herein refers to a lightweight non-woven materialused to contain and conceal an underlying absorbent core material;examples are the facing layer or materials that cover the absorbentcores of feminine hygiene garments, baby diapers and pants and adultincontinence garments.

“Crotch region” of an absorbent article as used herein refers to about50% of the absorbent article's total length (i.e., in the y-dimension),where the crotch point is located in the longitudinal centre of thecrotch region. That is, the crotch region is determined by firstlocating the crotch point of the absorbent article, and then measuringforward and backward distance of 25% of absorbent article's totallength.

“Cross direction (CD)”, “lateral” or “transverse” and the like as usedherein are used interchangeably and refer to a direction which isorthogonal to the longitudinal direction and includes directions within±45° of the transversal direction.

“Curing” as used herein refers to a process by which resins, binders orplastics are set into or onto fabrics, usually by heating, to cause themto stay in place; the setting may occur by removing solvent or bycross-linking so as to make them insoluble.

“Diaper”, “conventional diaper”, “diaper-like”, “diaper-like garment”and the like as used herein are used interchangeably and refer todisposable absorbent articles, which typically include a front waistportion and a back waist portion which may be releasably connected aboutthe hips of the wearer during use by conventional fasteners such asadhesive tape fasteners or hook and loop type fasteners. In use, thearticle is positioned between the legs of the wearer and the fastenersare releasably attached to secure the back waist portion to the frontwaist portion of the diaper, thereby securing the diaper about the waistof the wearer. The front waist portion and a back waist portion areconnected by relatively non-stretchable or stretchable members (the term“stretchable” as used herein refers to materials that are extensiblewhen forces are applied to the material, and offer some resistance toextension). Hence, such articles are generally not configured to bepulled up or down over the hips of the wearer when the fasteners areattached.

“Disposable” is used herein to describe articles that are generally notintended to be laundered or otherwise restored or reused (i.e., they areintended to be discarded after a single use and, preferably, to berecycled, composted or otherwise disposed of in an environmentallycompatible manner).

“Distribution layer”, “distribution region”, “distribution surface” or“distribution material” and the like as used herein are usedinterchangeably and refer to a layer having a larger capacity inwicking, dispersing and distributing liquids.

“Drylaying” as used herein refers to a process for making a nonwoven webfrom dry fibre; these terms apply to the formation of carded webs, aswell as to the air laying formation of random webs; a web of fibresproduced by drylaying is herein referred to as a “drylaid”; a drylaidweb bonded by one or more techniques to provide fabric integrity isherein referred to a “drylaid nonwoven”.

“Dry strength” as used herein refers to the strength of an adhesiveattachment determined in dry state conditions, immediately after dryingunder specified conditions or after a period of conditioning in thestandard laboratory atmosphere.

“Fabric” as used herein refers to a sheet structure made from fibres,filaments and/or yarns.

“Feminine hygiene garments” as used herein refer to absorbent hygienearticles intended to be worn by woman, for absorbing and containing bodyexudates.

“Fibre” as used herein refers to the basic threadlike structure fromwhich nonwovens, yarns and textiles are made. It differs from a particleby having a length at least 4 times its width; “Natural fibres” areeither of animal (wool, silk), vegetable (cotton, flax, jute) or mineral(asbestos) origin, while “Man-made fibres” may be either polymerssynthesised from chemical compounds (polyester, polypropylene, nylon,acrylic etc.) or modified natural polymers (rayon, acetate) or mineral(glass). “Fibre” and “filament” are used interchangeably.

“Film”, “foil” and the like as used herein are used interchangeably andrefer to a thin sheet of essentially non-absorbent material such asplastic or closed foams. In this invention it particularly refers tomaterials that do not correspond to non-wovens.

“Fluff pulp” as used herein refers to wood pulp specially prepared to bedrylaid.

“Front region” as used herein refers to the portion of an absorbentarticle or part thereof that is intended to be positioned proximate thefront of a wearer.

“Garment facing layer” as used herein refers to elements of the chassisthat form the outer surface of the absorbent article, such as the backsheet, the side panels, the waist fasteners, and the like, when suchelements are present.

“Heat activated adhesive” as used herein refers to a dry adhesive thatis rendered tacky or fluid by application of heat or heat and pressureto the assembly.

“Heat sealing adhesive” as used herein refers to a thermoplasticadhesive which is melted between the adherent surfaces by heatapplication to one or both of the adjacent adherent surfaces.

“Highloft” as used herein refers to general term of low density, thickor bulky fabrics.

“Hot-melt adhesive” as used herein refers to a solid material that meltsquickly upon heating, then sets to a firm bond upon cooling; used foralmost instantaneous bonding.

“Hydrophilic” as used herein refers to having an affinity for beingwetted by water or for absorbing water.

“Hydrophobic” as used herein refers to lacking the affinity for beingwetted by water or for absorbing water.

“Immobilisation layer” as used herein refers to a layer able to beapplied to the absorbent polymer material or absorbent polymer materialarea with the intent to compartmentalize, bond and/or immobilizeabsorbent material and/or layer.

“Join”, “joined” and “joining” as used herein refers to encompassingconfigurations wherein an element is directly secured to another elementby affixing the element directly to the other element, as well asconfigurations wherein the element is indirectly secured to the otherelement by affixing the element to an intermediate member or memberswhich in turn is or are affixed to the other element.

“Knitting” as used herein refers to the technique for interlocking loopsof fibres with needles or similar devices.

“Layer” refers to identifiable components of the absorbent article, andany part referred to as a “layer” may actually comprise a laminate orcombination of several sheets or webs of the requisite type ofmaterials. As used herein, the term “layer” includes the terms “layers”and “layered.” “Upper” refers to the layer of the absorbent articlewhich is nearest to and faces the wearer facing layer; conversely, theterm “lower” refers to the layer of the absorbent article which isnearest to and faces the garment facing layer. “Layer” is threedimensional structure with a x dimension width, y dimension length, andz-dimensions thickness or calliper, said x-y dimensions beingsubstantially in the plane of the article, however it should be notedthat the various members, layers, and structures of absorbent articlesaccording to the present invention may or may not be generally planar innature, and may be shaped or profiled in any desired configuration.

“Machine direction (MD)”, “longitudinal” and the like as used herein areused interchangeably and refer to a direction running parallel to themaximum linear dimension of the structure and includes directions within±45° of the longitudinal direction.

“Major surface” as used herein refers to a term used to describe thesurfaces of greatest extent of a generally planar or sheet-likestructural element and to distinguish these surfaces from the minorsurfaces of the end edges and the side edges, i.e., in an element havinga length, a width, and a thickness, the thickness being the smallest ofthe three dimensions, the major surfaces are those defined by the lengthand the width and thus having the greatest extent.

“Mass flow” as used herein refers to the flow of a liquid from oneabsorbent element or component to another absorbent element or componentby channel flow action.

“Mechanical bonding” as used herein refers to a method of bonding fibresby entangling them. This can be achieved by needling, stitching withfibres or by the use of high-pressure air or water jets and the like.

“Non-woven” as used herein refers to manufactured sheet, web or batt ofdirectionally or randomly orientated fibres, bonded by friction, and/orcohesion and/or adhesion, excluding paper and products which are woven,knitted, tufted, stitch-bonded incorporating binding yarns or filaments,or felted by wet-milling, whether or not additionally needled. Thefibres may be of natural or man-made origin and may be staple orcontinuous filaments or be formed in situ. Commercially available fibreshave diameters ranging from less than about 0.001 mm to more than about0.2 mm and they come in several different forms: short fibres (known asstaple, or chopped), continuous single fibres (filaments ormonofilaments), untwisted bundles of continuous filaments (tow), andtwisted bundles of continuous filaments (yarn). Nonwoven fabrics can beformed by many processes such as melt blowing, spunbonding, solventspinning, electro-spinning, and carding. The basis weight of nonwovenfabrics is usually expressed in grams per square meter (gsm).

“Pant”, “training pant”, “closed diapers”, “pre-fastened diapers”,“pull-on diapers” and “diaper-pants” and the like as used herein areused interchangeably and refer to absorbent articles which are typicallyapplied to the wearer by first leading the feet into the respective legopenings and subsequently pulling the pants from the feet to waist areaover the hips and buttocks of the wearer and which are capable of beingpulled up or down over the hips of the wearer. Typically, such articlesmay include a front waist portion and a back waist portion which may beconnected about the hips of the wearer by integral or releasablemembers. A pant may be preformed by any suitable technique including,but not limited to, joining together portions of the article usingrefastenable and/or non-refastenable bonds (e.g., seam, weld, adhesive,cohesive bond, fastener, etc.). A pant may be preformed anywhere alongthe circumference of the article (e.g., side fastened, front waistfastened).

“Polymer” as used herein refers to but is not limited to, homopolymers,copolymers, such as for example, block, graft, random and alternatingcopolymers, terpolymers, etc. and blends and modifications thereof.Unless otherwise specifically limited, the term “polymer” includes allpossible spatial configurations of the molecule and include, but are notlimited to isotactic, syndiotactic and random symmetries.

“Rear” as used herein refers to the portion of an absorbent article orpart thereof that is intended to be positioned proximate the back of thewearer.

“Resin” as used herein refers to a solid or semisolid polymericmaterial.

“Substantially cellulose free” as used herein refers to an absorbentarticle, structure or core, that contains less than 40% by weightcellulosic fibres, less than 20% cellulosic fibres, less than 5%cellulosic fibres, no cellulosic fibres, or no more than an immaterialamount of cellulosic fibres which do not materially affect the thinness,flexibility or absorbency thereof. This also encompasses completelycellulose free.

“Thermobonding” as used herein refers to a method of bonding fibres bythe use of heat and/or high-pressure.

“Thermoplastic” as used herein refers to polymeric materials that have amelting temperature and can flow or be formed into desired shapes on theapplication of heat at or below the melting point.

“Ultrasonic” as used herein refers to the use of high frequency sound togenerate localised heat through vibration thereby causing fibres to bondto one another.

“Water-absorbing”, “liquid-absorbing”, “absorbent”, “absorbing” and thelike as used herein are used interchangeably and refer to compounds,materials, products that absorb at least water, but typically also otheraqueous fluids and typically other parts of bodily exudates such as atleast urine or blood.

“Wearer facing layer” as used herein refers to elements of the chassisthat form the inner surface of the absorbent article, such as thetopsheet, the leg cuffs, and the side panels, etc., when such elementsare present.

“Weaving” as used herein refers to the process of interlacing two ormore sets of yarns at right angles to form a fabric; a web of fibresproduced by weaving is herein referred to as a “Woven”.

“Web material” as used herein refers to an essentially endless materialin one direction, i.e. the longitudinal extension or the length, or thex-direction in Cartesian coordinates relative to the web material.Included in this term is an essentially unlimited sequence of pieces cutor otherwise separated from an essentially endless material. Often,though not necessarily, the web materials will have a thicknessdimension (i.e. the z-direction) which is significantly smaller than thelongitudinal extension (i.e. in x-direction). Typically, the width ofweb materials (the y-direction) will be significantly larger than thethickness, but less than the length. Often, though not necessarily, thethickness and the width of such materials is essentially constant alongthe length of the web. Without intending any limitation, such webmaterials may be cellulosic fibre materials, tissues, woven or non-wovenmaterials and the like. Typically, though not necessarily, web materialsare supplied in roll form, or on spools, or in a folded state in boxes.The individual deliveries may then be spliced together to form theessentially endless structure. A web material may be composed of severalweb materials, such as multilayer non-woven, coated tissues,nonwoven/film laminates. Web materials may comprise other materials,such as added binding material, particles, hydrophilizing agents and thelike.

“Wet burst strength” is a measure of a layer's ability to absorb energy,when wet and subjected to deformation normal to the plane of the web.

“Wet strength” as used herein refers to the strength of an adhesiveattachment determined immediately after removal from a liquid in whichit has been immersed under specified conditions of time, temperature andpressure. The term is commonly used in the art to designate strengthafter immersion in water.

“Wetlaying” as used herein refers to the forming a web from an aqueousdispersion of fibres by applying modified paper making techniques; a webof fibres produced by wetlaying is herein referred to as a “wetlaid”.

“Wood pulp” as used herein refers to cellulosic fibres used to makeviscose rayon, paper and the absorbent cores of products such asfeminine hygiene garments, baby diapers and pants and adult incontinencegarments.

“X-y dimension” as used herein refers to the plane orthogonal to thethickness of the article, structure or element. The x- and y-dimensionscorrespond generally to the width and length, respectively, of thearticle, structure or element.

“Z-dimension” as used herein refers to the dimension orthogonal to thelength and width of the article, structure or element. The z-dimensioncorresponds generally to the thickness of the article, structure orelement.

The recitation of numerical ranges by endpoints includes all numbers andfractions subsumed within that range, as well as the recited endpoints.

The absorbent structure according to the invention, preferably asubstantially cellulose free structure, comprises a carrier layer, anauxiliary layer and an absorbent material provided between said carrierlayer and said auxiliary layer to form a sandwich wherein initialsmaller pockets (preferably more in relative amount as compared to latercompartments) and subsequently larger compartments (preferably less inrelative amount as compared to initial pockets) allows excellent fluidmanagement of the absorbent polymer material in dry, partially and fullyliquid loaded state. The absorbent structures according to the presentinvention allow sufficient internal immobilization of the absorbentpolymer material in dry state by providing well-designable customizedsmaller pockets containing the unexpanded dry materials and subsequentlyby providing well-designable customised bigger compartments containingthe wetted materials, while avoiding restraining or restriction of theswelling and volume-expanding absorbent material in wetted state,thereby preventing underutilisation, loss or negative impact on theirabsolute and relative performance, giving rise to superficial liquidmanagement surfaces.

In a preferred embodiment according to the invention the fluid andliquid management absorbent structure contains a pre-defined pattern ofsecondary attachments at least partially joining said enveloping layerstogether characterized in that the secondary attachments are loosened,dissolved, weakened and/or broken up as a result of exposing saidabsorbent structure to liquid, vapour and/or moisture. It should benoted that the secondary attachment can but do not have to bewater-sensitive, in other words they can thus also be water-insensitiveor wet-resistant, as the secondary attachments should preferably beallowed to detach by bringing the absorbent structure in contact withliquid, thus not necessarily the secondary attachments themselves haveto be wetted before the absorbent structures displays its fluid andliquid management. Next to more accurate prediction and development ofcustomised release times of the secondary attachments, this is alsoadvantageous since developing and controlling water-sensitive secondaryattachments bring much more complexity to the manufacturing process ofthe absorbent structures leading to slower production speeds, additionalenergy and material consumption, gives rise to higher prevalence ofdysfunctional and non-performing secondary attachment thus to bedisposed failing absorbent structures. The mere forces exerted by theswelling absorbent material should thus preferably be sufficient todetach the secondary attachments, independent of them being dry,partially wetted or fully wetted. Preferably the smaller-sized pocketsin dry state release under the influence of bringing the absorbentstructure into contact with water, thereby forming intermediate-sizedcompartment made up by the release expanded smaller-sized pockets and/orby the combination of multiple smaller-sized pockets. Preferably theseintermediate-sized pockets are formed when the absorbent structure ispartially loaded. Even more preferably the medium-sized compartmentsfrom partially wetted state enlarge even further under the influence ofbringing the absorbent structure into contact with water or uponadditional swelling of the absorbent polymer material, thereby formingmaximum-sized compartments made up by the release expanded smaller-sizedpockets and by the combination of multiple smaller-sized pockets andmedium sized compartments. Preferably these maximum-sized pockets areformed when the absorbent structure is almost fully wetted. Thiscontrolled and continuous expansion during the wetting process resultsin unseen fluid management qualities and moreover allows for liquidmanagement superficial structures. This is unseen in the prior art andis highly desirable. Preferably also a pre-defined grid of primaryattachments is present throughout the majority of the surface area ofthe absorbent structure which remain substantially intact under normalusage conditions. The primary attachment can serve the overallstructural and functional integrity of the absorbent structure, increasethe fluid management systems and/or help with the creation ofin-homogenous liquid management surface structure of the absorbentstructure. Absorbent structures according to a preferred embodiment ofthe invention contain absorbent polymer material, more preferablyabsorbent particulate polymer material such as highly permeable SAP.

In a preferred embodiment according to the invention a single absorbentlayer substantially cellulose free absorbent structure for use in anabsorbent article is measuring about 10 cm in width by about 40 cm inlength, having an average dry thickness from about 0.1 to about 10 mm,more preferably from about 0.5 to about 5 mm, most preferably from about1-3 mm would contain about 5-25 grams absorbent polymer material, morepreferably about 10-20 grams, more preferably 11-15 gram, mostpreferably about 12-14 grams which would initially be pocketed in about50-800 small pockets, more preferably about 100-700 pockets, morepreferably about 200-600 pockets, more preferably about 300-500 pockets,more preferably about 350-450 pockets and most preferably around 1pocket per cm² absorbent structure surface, which would subsequently begradually released to ultimately form about 1-50 compartments, morepreferably about 3-30 compartments, more preferably about 5-25compartments, more preferably about 10-20 compartment and mostpreferably about 1 compartment per 15 cm² absorbent structure surface.Pockets are preferably identical and square-, round- or honeycomb shapedand uniformly and homogenously distributed across the absorbentstructure, the compartments are preferably longitudinally distributedand rectangle- or ellipsoid-like shaped having adequate perimetersealing at the absorbent article edges to avoid liquid managementstructures guiding and channelling the liquid to edges of the absorbentstructure, where certainly the edges of the crotch regions have to beavoided. In essence the shape of the smaller pockets try to accommodatethe maximum amount of absorbent polymer on the available surface area,while the bigger compartments try to accommodate the maximum expansionvolume of the wetted absorbent polymer materials while ensuring internalfluid management and external liquid management via surface structures.The absorbent polymer material will furthermore preferably be profiledthroughout the surface in these dry pockets, hence the need for primaryattachment grid and secondary attachment patterns having well-definedand accurate bonding strength to accommodate fluid management and liquidmanagement surface structures according to the invention. The absorbentstructure will preferably be complemented by about 30-70 gsm, morepreferably about 40-60 gsm and most preferably about 50 gsm highloftacquisition layer and/or similar amounts of curly fibers as distributionlayer to allow fast uptake and distribution within the absorbentarticle, subsequently being enveloped in a liquid permeable topsheet andliquid impermeable breathable backsheet to allow implementation withinan absorbent article such as baby diaper or pants.

While preferably such absorbent structure volume increases are result oftemporary secondary attachment patterns made up for instance fromultrasonic bonds, preferably the absorbent structures are designed incombination with substantially permanent primary attachment grids forinstance also made up by ultrasonic bonds, allowing the release ofbigger volumes from the initial smaller volumes by detachment of thesecondary attachments, while keeping absorbent polymer integrity andcoherence in light of excellent fluid management via the primaryattachment pattern safeguarding structural and functional integrity. Inan alternative embodiment however these absorbent structure volumeincreases are the result of using flexible, extensible, elastic,stretchable and/or elastomeric materials such as for instance elasticnon-woven and/or breakable material such as for instance semi-rigid,rigid and/or stiff paper or tissue respectively allowing additionalexpansion from and/or breaking up from smaller to larger volumes.

In certain embodiments according to the present invention all or some ofthe secondary attachments may for instance be maintained during partialloading of the absorbent structure, while they will only become detachedin fully bodily exudates loaded state. In this way initial contact ismaintained until swelling forces of the absorbent structure take theupper hand. This de-bonding does preferably not influence the primaryattachments, thereby still ensuring functional and/or structuralintegrity of the absorbent structure and absorbent polymer materialarea, while however not restraining the swelling of the absorbentpolymer material so as to decrease liquid absorption and retentioncapacity. By preferably not relying on wet-soluble, wet-sensitive ornot-wet-resistant secondary attachments the detachment process of thesecondary attachment patterns according to the invention can be bettercontrolled and predicted, since such absorbent structures and secondaryattachment patterns in use, such as for instance used in absorbentarticles such as a baby diaper or pants, will not be prematurelyreleased due to the mere wetting of the (wet-sensitive) attachment meansbut will only be released when the to be expected and required forcesderiving from movement, article strain and absorbent polymer materialswelling have been reached. This is especially advantageous insubstantially cellulose free absorbent articles as they specificallyhave to avoid free migration and movement of dry or partially dryabsorbent polymer materials in light of lumping, gel blocking andoverall absorbent material performance.

In a preferred embodiment the absorbent structure immobilizes, retainsand/or restrains the particulate material and the attachments seal, bondand/or join at least part of the pockets and/or outer layers togethervia ultrasonic bonding, thermo-bonding, pressure-bonding and/orglue-bonding means. These attachments preferably form and/or definepockets which can contain particulate material, whereby the attachmentregions comprise essentially and preferably no particulate material.Preferably these attachments are made up from discrete shape rather thansubstantially continuous lines so as to better control the bonding anddebonding process in line with specified bonding strengths for thoseprimary attachments grids and secondary attachment patterns within thatabsorbent structure according to that embodiment of the presentinvention. The use well-design dots for instance can be located, shapedand sized in such a manner so as to gradually release the secondaryattachment pattern while steadily preserving the primary attachmentpatterns during any given absorbent structure embodiment. Preferablythis is done by the very accurate ultrasonic bonding as opposed to thethermo-mechanical calendaring for instance which are very difficult tocontrol in light of their generated attachment tenacity. Also suchcalendar systems are caused to be performing very poorly in case anyabsorbent material is trapped in between the attachments. The absorbentstructure according to the present invention overcome these problems.Preferably the absence of an excess or the complete elimination ofsynthetic immobilisation admixtures (e.g. adhesive and binders, such asthermoplastic glues and webs) used for covering, restraining or bondingabsorbent polymer materials makes the structure technically,environmentally and economically very favourable. In an alternativeembodiment, the composite structure is covered with such thermoplasticmaterials, glues, binders and/or adhesives to fixate, pocket,encapsulate, bind and/or join these particulate material clusters toand/or in between one or more layers. Additional materials and/or layersto provide extra functional and/or structural advantages such asstrength, acquisition, absorption, distribution, transport, retention,etc. may also be incorporated.

The absorbent structure, preferably substantially cellulose free,according to the invention has several embodiments and preferredembodiments for use in absorbent products such as for instance:

An absorbent structure comprising:

-   -   a) a carrier layer; and    -   b) an auxiliary layer; and    -   c) an absorbent material provided between said carrier layer and        said auxiliary layer wherein pockets release extra volume as a        result of exposing said absorbent structure to liquid.

An absorbent structure comprising:

-   -   a) a carrier layer; and    -   b) an auxiliary layer; and    -   c) an absorbent material provided between said carrier layer and        said auxiliary layer wherein relative smaller sized pockets        release extra volume so as to form relative bigger sized        compartments as a result of exposing said absorbent structure to        liquid.

An absorbent structure comprising:

-   -   a) a carrier layer; and    -   b) an auxiliary layer; and    -   c) an absorbent material provided between said carrier layer and        said auxiliary layer wherein a plurality of smaller sized        pockets release extra volume so as to form relative fewer bigger        sized compartments as a result of exposing said absorbent        structure to liquid.

An absorbent structure for use in an absorbent article comprising:

-   -   a) a carrier layer; and    -   b) an auxiliary layer; and    -   c) an absorbent material provided between said carrier layer and        said auxiliary layer wherein a plurality of smaller sized        pockets release extra volume so as to form relative fewer bigger        sized compartments as a result of exposing said absorbent        structure to liquid wherein at least some secondary attachments        form pockets characterized in that when the secondary        attachments are loosened as a result of exposing said absorbent        structure to liquid they form compartments.

An absorbent structure for use in an absorbent article comprising:

-   -   a) a carrier layer; and    -   b) an auxiliary layer; and    -   c) an absorbent material provided between said carrier layer and        said auxiliary layer wherein a plurality of smaller sized        pockets release extra volume so as to form relative fewer bigger        sized compartments as a result of exposing said absorbent        structure to liquid wherein at least some secondary attachments        join said carrier layer and said auxiliary layer together to        form pockets characterized in that when the secondary        attachments are loosened as a result of exposing said absorbent        structure to liquid they form compartments.

An absorbent structure for use in an absorbent article comprising:

-   -   a) a carrier layer; and    -   b) an auxiliary layer; and    -   c) an absorbent material provided between said carrier layer and        said auxiliary layer wherein a plurality of smaller sized        pockets release extra volume so as to form relative fewer bigger        sized compartments as a result of exposing said absorbent        structure to liquid wherein at least some primary and secondary        attachments join said carrier layer and said auxiliary layer        together to form pockets characterized in that when the        secondary attachments are loosened as a result of exposing said        absorbent structure to liquid they form compartments, whereas        the primary attachments remain substantially intact.

An absorbent structure for use in an absorbent article comprising:

-   -   a) a carrier layer; and    -   b) an auxiliary layer; and    -   c) an absorbent material provided between said carrier layer and        said auxiliary layer wherein a plurality of smaller sized        pockets release extra volume so as to form relative fewer bigger        sized compartments as a result of exposing said absorbent        structure to liquid wherein at least some primary and/or        secondary attachments join said carrier layer and said auxiliary        layer together to form pockets characterized in that when the        secondary attachments are loosened as a result of exposing said        absorbent structure to liquid the absorbent structure swells        in-homogenously so as to form liquid management surface        structure.

In a preferred embodiment the following is provided: A substantiallycellulose free absorbent structure comprising a carrier layer, anauxiliary layer and an absorbent particulate polymer material therebetween, the carrier layer and auxiliary layer being at least partiallyjoined together by attachment regions made up of substantially permanentprimary attachment grids having relative higher bonding strength and/orsubstantially temporary secondary attachment patterns having relativelower bonding strength, so as to form a sandwich-like compositestructure containing clustered absorbent particulate polymer materialsprovided in at least some of the unattached regions between the carrierlayer and auxiliary layer thereby forming an absorbent polymer materialarea, the plurality of smaller-sized pockets of substantially equalthickness made up by at least substantially temporary secondaryattachments define spaces which immobilize the available dry volumeabsorbent polymer material, the substantially temporary secondaryattachment being gradually releasable as a result of exposing theperipheral absorbent polymer material to liquid so as phase in anintermediate volume increase to fewer medium-sized compartmentsimmobilising the partially wetted absorbent polymer material,subsequently resulting in still fewer maximum-sized compartmentsimmobilising the wetted absorbent polymer material. Preferably it showsnon-homogenous swelling due to non-homogeneous swelling of the absorbentpolymer materials and/or releasing of the secondary attachments so as tofrom liquid management structures.

Prior art absorbent structures swell substantially homogeneous andcontinuous until the available liquid uptake capacity of the absorbentmaterial is reached and/or the available free volume and space withinthe various absorbent structure boundaries is taken up by the swollenand volume-expanded absorbent materials. The placing of too muchabsorbent polymer material in smaller and confined pockets which do nothave the volume expanding capacities according to the present inventionthus lead to underused absorbent material capacities, while theoverfilled pockets often result in undesirable lumpy pocket feelings forthe handler and user and in extreme cases may cause the pockets tounintentionally rupture thereby expelling the swollen absorbentmaterials into contact with the user which is to be avoided.

Other absorbent structures foresee in dry state the necessary swellingvolume for their subsequent wetted and swollen absorbent polymermaterial by providing larger and spacious pockets prior to use. However,especially in substantially cellulose free absorbent structure, therequired volume leads to the absorbent material not being sufficientlyimmobilized resulting in free migration, moving and clustering togetherleading to extremely poor fluid and liquid management. Furthermore theclustering together of absorbent material in too large pockets in drystate causes severe gel-blocking when wetted and more over decreases theoverall fit, comfort and discreetness due to the fact these largepockets cause the absorbent polymer material to form significant volumesin parts of the large pockets during usage which are felt by the user inuse, which is highly undesirable. The apparent gel-blocking leads tovery poor usage of the expensive absorbent polymer materials.

Nevertheless it has been found when absorbent polymer material absorbsliquid and swells it actually performs much more rapidly, effectivelyand efficiently when it has been disposed in pockets or arrangements.These predefined locations together with the meticulous dosing ofabsorbent polymer material can thus help to obtain optimal absorbency,fit and/or comfort. It is desirable for absorbent polymer material toremain in its intended location, while unwanted migration anduncontrolled movement thereof within the absorbent structure should beavoided. However the absorbent material is very desirably alsoimmobilized and/or restrained via an absorbent structure in such a waythat the absorbent particulate polymer material performs both inpartially liquid loaded as well as in fully liquid loaded conditiontaking in mind required volume expansion for material and structuralperformance.

The absorbent structure according to present invention is thereforedistinguished by its capability to firmly pocket, immobilize and/orrestrain absorbent material within the dry state while allowingadditional, predetermined, phased and controlled expansion from amultitude of smaller-sized pockets to fewer but bigger-sized unleashedcompartments during the wetting of the absorbent structure, thuscreating additional (yet unavailable) space, volume and surface area inlight of optimal expansion, swelling and/or loading of the absorbentmaterial. While the substantially permanent primary attachment gridswill essentially help to safeguard the structural integrity of theabsorbent structure since they are substantially resistant to the forcesexerted upon them during the wetting and using of the absorbent article,the substantially temporary secondary attachment patterns will allow therise of unprecedented functionalities, while nevertheless securelyencapsulating the absorbent material during gradual phased expansion andswelling.

The absorbent structure attachment grid and pattern is preferably inline with the to be exerted forces generated by the user and by theavailable and usable absorbent material when being loaded fromsubstantially dry to a partially loaded up to fully liquid loaded state.The primary attachments in essence retain more integrity during andafter absorbent structure absorption than the secondary attachments. Thedifference in bonding strength between the primary attachments and thesecondary attachments allows the carrier layer and auxiliary layer toseparate between the multiple primary attachment regions, respectivelyat the secondary attachment regions, thus releasing additional space andvolume to allow further and free expansion of the absorbent material inthe partially or fully liquid loaded state as opposed to the dry state.This release is brought in line with the volume swelling.

The unlocking of the extra volumes and space during usage only, leads toseveral manufacturing, storage and transport advantages, since theabsorbent materials can now be positioned, clustered and immobilizedmore accurately and effectively, as the removal of initial restrainingmeans during use allows for deferred fluid and liquid management systemsleading to excellent performance and significant raw material savings.Better and controlled liquid wicking and dispersion thus leads toimproved fluid communication from less absorbent (e.g. saturated) to themore absorbent area's (e.g. unsaturated).

For reasons of further improved absorbency, fluid distribution,transport, retention and lower amount of leakages and rewet-values, itis preferably desirable for these absorbent structures to have outspokenmacroscopic liquid management surface structures such as heights andelevations and/or depressions and valleys which can act as channels,canals and/or embankments to guide the liquid in a desired manner. Theabsorbent structure comprises a carrier layer, an auxiliary layer and anabsorbent material sandwiched there between wherein primary attachmentsand secondary attachments bond said carrier layer and said auxiliarylayer together characterized in that the absorbent structurenon-homogeneously swells to form a superficial liquid-managing surfacestructure as a result of exposing the absorbent structure to liquid.

For reasons of optimal flexibility, fit, comfort, discreetness,transportation and storage efficiency, it is desirable for suchthree-dimensional macroscopic surface structures to appear and functiononly when needed, i.e. when the product is partially and/or fully wettedby liquid, and are thus preferably not yet present prior to the usage ofthe absorbent structure. The invention allows for indirectfunctionalities, whereby ‘hidden’ features in dry state are essentially‘unleashed’ by wetting, thereby ‘revealing’ essentially thethree-dimensional structures with higher) elevated and/or low(er)depressed functional and structural parts of the absorbent structure.The three-dimensional swelling of the absorbent structure can be causedby differential swelling of the absorbent polymer material or by thedifferential grid and pattern of bonding and debonding attachments, orby a combination thereof. In a preferred embodiment, the absorbentstructure comprises absorbent materials different in volume absorptioncapacity, by at least 25%, preferably at least 50%, most preferably atleast 100%. By way of example an originally flat cuff being for instanceattached between two areas of high absorption would be freed and erectitself when these areas take up liquid and swell.

The inventor has found that the ability to create macroscopic surfacestructures with internal, incorporated and superficial liquid managementsystems allow unseen fluid management by enabling liquid guidancetowards desired locations with additional uptake, distribution,transport and containment opportunities as effect and thus ensuring asignificant increase in efficiency and effectiveness of raw materialusage while limiting gel blocking, reducing rewet, minimizes leakage andfailure. Preferably the liquid is guided towards the entire surface ofthe absorbent structure with the exception of the side edges to minimizeleakages and product failures.

Ideally the liquid taken up by the absorbent structure and the swellingand volume increase resulting therefrom is in line with the respectivespaces and volumes created by the incremental debonding and loosingprocess of the attachment patterns. While the dry immobilisation of thelower volume absorbent material is secured in the small(ler) pocketsformed by the combination of the primary and secondary attachments, thewet immobilisation of the wetted higher volume absorbent material iscontinuously ensured by the expanding big(ger) compartments defined byintact primary attachments after partial or full release of thesecondary attachment patterns under the influence of liquid, vapourand/or moisture. As the absorbent material gains significant volume itis thus important to restrain the absorbent material continuously.Well-designed phased absorbent structures allow gradual expansion of theabsorbent material without too little or too excessive restraining andtoo late or too early detachment of the secondary attachments during thegradual wetting and swelling process. The bonding strength shouldsuffice the parameters of the absorbent structure and will depend on thearticle, its product size and shape and the required duration of theusage and performance.

It is noted that when stated primary attachments remain substantiallyintact under influence of liquid, reference is preferably being made tocharacteristics under relatively normal wearing/usage conditions,typical usage timing, average liquid amounts and intervals at room orbody temperatures without taking into account exaggerated, severe and/orextreme conditions such as for example abnormal large amounts of litresof liquid during multiple days of intense contact. In such case,although not preferred, the initially wet-resistant primary attachmentsmight become loosened, detached or broken up after all. It would beclear from the above that such primary attachments eventually turninginto secondary attachments after being exposed to prolonged and/or moreintense usage conditions than normal are also envisaged under thisinvention.

Unlike previously existing absorbent articles and methods from the priorart limited by permanent or fully releasable immobilization and/orrestraining means leading to unsatisfactory absorbency, distribution andretention parameters combined with limited flexibility, fit and wearingcomfort, the present invention overcomes various problems relatingthereto and deriving therefrom by having absorbent material containingpockets and compartments with pre-defined and well-managed permanentgrids and temporary patterns leading to gradual volume expansion. Thepresent invention furthermore overcomes various problems by havingwetted absorbent material forming obstacles and liquid guides therebyproviding physical and chemical barriers and blockages preventingleakage and/or providing extra fluid distribution and transport. Morespecifically the invention allows increased absorbent material expansionand swelling within the unleashed compartments, while additionaldistribution and transport arises within and in between the absorbentpolymer material clusters which have until now been underused andunappreciated.

The present invention thereby does not only provide for an efficaciouscompartmentalization and restraining of absorbent materials in dry,partially and fully liquid loaded stated, it also allows a significantincrease in efficiency and effectiveness of raw materials available inthe absorbent structure within partially and fully liquid load state,increases overall absorbency and retention capacities and limits gelblocking, reduces rewet and minimizes leakage.

In a second aspect, the present invention provides an absorbent articlecomprising, at least in the front half of the absorbent article, anabsorbent structure according to an embodiment of the invention. In apreferred embodiment, the absorbent article comprises an absorbentstructure comprising a carrier layer and auxiliary layer, whereby theupper surface of the carrier layer is facing the wearer's skin and alower surface of the auxiliary layer is facing the garment of thewearer. The absorbent material is preferably in direct contact with thelower surface of the auxiliary layer and the upper surface of thecarrier layer, however additional fabric, non-woven, woven, tissueand/or paper layer can be provided to accommodate further fluidmanagement and integrity.

It is known that for most absorbent articles, for instance for articlessuch as feminine hygiene garments, baby diapers, baby pants and adultincontinence products, that liquid discharge occurs predominantly in thefront half. It is therefore advantageous to provide an improvedabsorbent article with an absorbent structure according to an embodimentof the invention in that area where fluid loading and uptake requirementis highest. Obviously, an absorbent article comprising an absorbentstructure according to an embodiment of the invention which is entirelyor partially located in either the front, crotch and/or back region ofthe absorbent article, such as for instance a baby diaper, is alsocovered under this invention. Any combinations thereof are hereby alsoencompassed.

In the hygiene industry, absorbent articles are specifically designed toabsorb, distribute and retain bodily exudates. Apart from taking upliquid and retaining it within the absorbent structure of the absorbentarticle, the absorbent articles are also intended to satisfactoryprevent bodily exudates from soiling, wetting, or otherwisecontaminating clothing or other articles, such as bedding, that maypossibly or come in contact with the wearer. A disposable absorbentarticle, such as a disposable diaper, may be worn for several hours in adry state and/or in liquid loaded state. Accordingly multiple attemptshave been made toward improving the fit and wearing comfort of theabsorbent article, both when the article is dry and when the absorbentarticle is fully or partially loaded with bodily exudates, whileenhancing the absorption, distribution and retention functions of theabsorbent article. Flexible, thin, light-weight and discreet absorbentarticles are also here greatly preferred.

A typical absorbent article has a crotch width of about 100 mm and anaverage core length of about 500 mm. An absorbent article with a crotchwidth of this dimension provides improved consumer comfort. An absorbentstructure according to the present invention achieves a crotch width ofpreferably less than 85 mm, 80 mm, 75 mm, 70 mm, 65 mm, 60 mm, 55 mm or50 mm and a core length of preferably less than 500 mm, 450 mm, 400 mm,350 mm or 300 mm. Hence, preferably an absorbent structure according tothe present invention has a crotch width and a core length in line withthe above dimensions.

In a third aspect, a method and apparatus to produce an absorbentstructure according to an embodiment of the invention used as absorbentcore in a feminine hygiene garment, baby diaper, baby pants or adultincontinence garment product. While particular embodiments of thepresent invention are illustrated and described, it would be obviousthose skilled in the art that various other changes and modificationscan be made without departing from the spirit and scope of theinvention.

Method and apparatus for the manufacturing of an absorbent structure foruse in an absorbent article comprising the steps of:

-   -   providing a carrier layer;    -   covering the carrier layer with an absorbent material wherein        said absorbent material comprises    -   i) an absorbent polymer material, and    -   ii) from zero to an amount less than about 40 weight percent        absorbent fibrous material, based on the weight of absorbent        polymer material;    -   covering the absorbent material with an auxiliary layer which is        joinable to the carrier layer; and    -   joining the auxiliary layer to the carrier layer thereby forming        primary attachments and secondary attachments that define        pockets there between wherein the absorbent material is held in        at least one of the pockets, characterized in that, the        secondary attachments are loosened, preferably to form larger        compartments, as a result of exposing the absorbent structure to        a liquid whereas the primary attachments remain substantially        intact.

Examples are used below for further non-limitative illustration of theinvention.

With reference to FIGS. 1 A-D, 2 and 3, the absorbent structure 14includes at least one carrier layer 101 and at least one auxiliary layer102, and absorbent material 110. The carrier layer 101 and auxiliarylayer 102 are joined via secondary attachments 115, optionally via asecondary attachment media such a for instance glue or hot-melt, andpreferably also joined together via primary attachments 111, optionallyvia primary attachment media such as for instance an adhesive or binder.

It should be noted although absorbent structures using secondaryattachments 115 as well as primary attachments 111 are very muchpreferred, absorbent structures 14 only using secondary attachments 115without the use of primary attachments 111 are also covered by thisinvention. One might for instance think about a combination of severalpieces of absorbent segments combined to form an absorbent structure 14which is only using secondary attachments 115 within the absorbentsegments so upon wetting to come from a multitude of dry segments withsmaller pockets 130 to a multitude of wetted segments with largercompartments. Various combinations, shapes and sizes are of coursepossible and are hereby encompassed by the present invention.

Referring to FIG. 1B, a carrier layer 101 and an auxiliary layer 102 isprovided. The carrier layer 101 is covered on one side by discreteamounts of absorbent material 110. The absorbent material 110 is coveredby an auxiliary layer 102. The auxiliary layer 102 lies on top of theabsorbent material 110 and is joined at regular intervals a distributionlayer 100 a or wicking layer 100 b thereby providing pockets 130 holdingthe absorbent material 110. The absorbent material 110 preferablycomprises absorbent particulate polymer particles, but in additionabsorbent fibrous materials can be used. Preferably the amount ofabsorbent fibrous material used is less than 10 weight percent based onthe total weight of absorbent polymer material.

Referring to FIG. 1C, it has been found that absorbent structures 14 canbe formed by combining two layers of absorbent material 110. Theabsorbent structure 14 as shown comprises one carrier layer 101, twolayers of absorbent material 110 and two auxiliary layers 102. When twodiscontinuous layers of an absorbent material 110 are used, being one onthe wearer facing surface and one on the garment facing surface, theywould be typically arranged in such a way that the compartments 130containing the absorbent material 110 from one storage layer are alignedwith the compartments 130 containing the absorbent material 110 from theother storage layer in order to have the attachments from both layersadjacent to one another. In another alternative embodiment, however, thecompartments 130 and the respective attachments are offset one another.

Referring to FIG. 1D, it has also been found that absorbent structures14 can be formed by combining two or more layers of absorbent material110. The absorbent structure 14 as shown comprises two layer ofabsorbent material 110, two carrier layers 101, and two auxiliary layers102. When two discontinuous layers of an absorbent material 110 areused, they would typically be arranged in such a way that the pockets130 containing the absorbent material 110 of one storage layer faces thepockets 130 containing the absorbent material 110 of the other storagelayer. In an alternative preferred embodiment, however, the attachmentsare offset and do not face each other. Hence preferably, when twostorage layers are joined, this is done such that the first carrierlayer 101 of the first storage layer faces the auxiliary layer 102 ofthe second storage layer, while the auxiliary layer 102 from upperstorage layer is situated on the wearer facing surface and the carrierlayer 102 from lower storage layer is situated on the garment facingsurface of the sandwiched structures.

Typical examples of methods used to join material and layers to eachother are by way of example, but are not limited to, the use of anadhesive such as for instance pressure sensitive adhesive, curing,chemical links such as for instance hydrogen and covalent bonds or viathe use of ultrasonic and/or other thermal, mechanical orthermo-mechanical attachment techniques such as for instance heatsealing, needling, air, entanglement, resistance and water jet pressure,and the like.

However, if the carrier layer 101 and the auxiliary layer 102 are solelyattached to one another for example via an area of mechanical resistanceor entanglement, or via an area on which the layers are fused together;without the need of any additional bonding or joining agent, noattachment media is provided. In a preferred embodiment, the primaryattachments 111 and secondary attachments 115 are solely made up byultrasonic thermo-sealing, which are preferably water-insensitive.Typically thermo-sealing areas of the primary attachments 111 arerelatively large(r) in surface, tenacity and/or integrity (than thethermo-sealing area's of the secondary attachments 115), resulting in anabsolute or relative high(er) separation force. In general, theattachments can come in various sizes and shapes, such as round,elliptic, rectangular or square shapes but it is preferred to providethem with rounded edges to inhibit the carrier layer 101 and auxiliarylayer 102 from tearing apart during use. Preferably primary attachments111 are arranged in a pattern consisting of rounded elements of whicharound 50% are oriented along an X-axis, and the remainder along aY-axis. Combinations of elliptical-like shapes, such as uni-dimensionaland bi-dimensional shapes serve as excellent primary attachments 111.

It is also preferred to design the attachments so that they have anaverage surface size of at least about 0.5 mm², preferably at leastabout 1.0 mm², 2 mm² or 3 mm², more preferably at least about 16 mm².Also the density of the attachments can vary, depending on the surfacesize of the individual attachments and desired separation forces. Forattachments with a surface area smaller than 1 cm² for instance, it isrecommended to use a density of at least about 100 per m². In anotherembodiment of this invention, the primary attachments 111 are arrangedin a primary attachment grid composed of continuous lines so as to allowfor additional liquid distribution and transport, for a high separationforce and high resistance against the propagation of an eventual cracksor fissures in the pockets 130. The primary attachment pattern iscarefully designed so that in a wetted state, the swollen materialremains stabilized around the locations where it was restrained and/orimmobilized in dry state. Failure to do so would result in breaking-upand/or displacement of the wet absorbent material, resulting indefective fluid management and to loss of performance, reduced fit andcomfort, even full failure. The primary attachment pattern alsoaccommodates the liquid management surface structures.

Apart from the primary attachments 111 and secondary attachments 115,there are also unattached regions 119, where there is substantially noattachment, bond and/or joint between the carrier layer 101 andauxiliary layer 102, thereby providing pockets 130 in which theabsorbent material 110 can be located to form well-designed clusters.The primary attachments 111 correspond with a primary attachment grid,whereas the secondary attachments 115 correspond with a secondaryattachment pattern. As the secondary attachment pattern will releaseunder the swelling force of the absorbent materials and/or under theinfluence of water, the secondary attachment 115 should have a relativelow separation force is use. Preferably the separation force necessaryto break the attachment will be lower than about 5.0 N/cm, morepreferably lower than about 2.5, 2.0 or 1.0 N/cm, even more preferablylower than about 0.75, 0.5 or 0.25 N/cm and most preferably lower thanabout 0.20 or 0.10 N/cm in use.

The bonding strength, such as for example the dry strength, wet burststrength and/or wet strength, should suffice all required parameters ofthe absorbent structure and will amongst others depend on the absorbentarticle, its product size and shape and the required duration of theusage and performance. The specific structural and functional strengthof the attachments in between the auxiliary layer and the carrier layerand/or the different wet strengths in between the attachments of theprimary attachment regions and the secondary attachment regions allowsfor more efficient design and usage of the absorbent structures leadingto more, faster and enhanced absorption, distribution and retention ofliquids, such as bodily exudates. Moreover it also allows for better andcontrolled liquid wicking and dispersion within said absorbent storagelayer, leading to more efficient and effective fluid communication ortransport from the less absorbent area's (e.g. saturated) to the moreabsorbent area's (e.g. unsaturated).

In one embodiment of this invention, a specific hydro-soluble orwater-sensitive secondary attachment is used, for instance in the formof an adhesive as secondary attachment medium. In a more preferredembodiment however, both layers are thermo-sealed together, mostpreferably by wet-insensitive ultrasonic bonding, without any syntheticattachment admixtures. The thermo-sealing areas of the secondaryattachments 115 being relatively small(er) in surface, tenacity orintegrity (than the primary attachments 115) resulting in an absolute orrelative low(er) separation force. The thermo-sealing areas can come invarious sizes and shapes, but it is preferred to provide at least onesharp edge to facilitate the carrier layer 101 and auxiliary layer 102to tear apart. Combinations of circle-like shapes, such as round and dotshapes are also preferred as secondary attachments 115. Elimination ofattachment media leads to lower raw material and production costs andenvironmental/sustainable absorbent structures. It is furthermoreadvantageous to use thermo-sealing as attachment means, rather thanusing adhesive, as the production cost is then usually substantiallylower and one can claim to be ‘adhesive-free’, a claim which isimportant to environment-conscious consumers.

As carrier layer 101 and/or auxiliary layer 102, having a typical basisweight in the range of 3-400 gsm, more preferably 5-75 gsm, one canchoose from a variety of materials such as but not limited tohigh-lofts, airlaids, rigid, stretchable or elastic non-wovens or awoven fabric, wetlaid material such as cellulose tissue, paper, film,tissue, perforated films, foam material, thermoplastic material, layersof adhesive or whatever material suitable within the absorbent structure14. The sandwich layers can be made out of the same or differentmaterials having different compositions, weights and/or structures. In apreferred embodiment, at least one of the layers is liquid permeableover at least part of its surface so that liquids can be taken up in theZ-direction. In another embodiment both the carrier layer 101 and theauxiliary layer 102 are liquid permeable. In yet another preferredembodiment, one of the layers is a liquid permeable non-woven materialand the other layer is a substantially liquid-impervious and possiblybreathable polyethylene (PE) film, whereby the non-woven is positionedat the expected liquid flow such as the wearer-facing side of theabsorbent structure 14 in case of an absorbent article such as a diaper,and the PE film is positioned away from the expected liquid flow such asthe garment-facing side of the absorbent structure in case of anabsorbent article such as a baby diaper. In this case, one could forinstance select 22 gsm polypropylene non-woven material from Albis and20 μm breathable polyethylene film from Nuova Pansa. The use of theterminology ‘carrier layer’ by no means implies that the fabric shouldbe strong enough to support the structure or should be situated at thelower region of the absorbent structure 14. Nor does ‘auxiliary layer’imply that this layer should have a lesser function or should by analogybe situated at the upper region of the absorbent structure 14.

In an alternative embodiment the carrier layer 101 and/or auxiliarylayer 102 can be an adhesive in combination with other immobilisationdiluents such as tackifying resins, plasticizers and additives such asantioxidants, but could well be any other composition able tosubstantially immobilise absorbent polymer material 110 within theabsorbent structure 14 according to the invention. Some immobilisationmaterials are thermoplastic others are not, while some initiallythermoplastic materials may lose their thermoplastic behaviour due to acuring step, e.g. initiated via heat, UV radiation, electron beamexposure or moisture or other means of curing, leading to theirreversible formation of a cross-linked network of covalent bonds. Theadhesive and binders are preferably applied by a nozzle system.Preferably, a nozzle system is utilised which can provide a relativelythin but wide curtain of binder. This glue curtain can be continuous ordiscontinuous, so as to be applied in a homogeneous or heterogeneoussurface or can be applied in various combinations of lines, grids,spirals, figures, spots, dots, etc. either in a determined orundetermined location of the target surface and/or any combinationthereof. Those materials having lost their initial thermoplasticbehaviour are herein also understood as immobilisation materials. It hasbeen found that compositions most useful for immobilizing absorbentpolymer materials are those which combine controlled cohesion andadhesion behaviour. Adhesion is preferred to ensure that the layermaintains sufficient contact with the absorbent polymer material 110.Cohesion ensures that the attachment does not unintentionally detach orkeeps attached, in particular in response to external forces, and namelyin response to strain. The attachments are subject to external forcesduring usage and when the absorbent structure swells due to the acquiredliquid.

In an alternative embodiment of the present invention the absorbentstructure 14 comprises an additional distribution layer 100 a whichhelps to additionally absorb, distribute and transport liquids andhaving a capability to disperse the liquid permeating within saiddistribution layer 100 a from the less absorbent area's (e.g. saturated)to the more absorbent area's (e.g. unsaturated).

In an alternative embodiment of the present invention the absorbentstructure 14 comprises an additional liquid-impermeable, eitherhydrophilic or hydrophobic, wicking layer 100 b which helps to wick andtransport liquids and having a capability to disperse the liquid overthe surface of said wicking layer 100 b from the less absorbent area's(e.g. saturated) to the more absorbent area's (e.g. unsaturated).

In an alternative embodiment of the present invention the absorbentstructure comprises an additional thermoplastic immobilisation layersuch as thermoplastic adhesive or binder (e.g. hot-melt) which helps toimmobilize the absorbent materials 110 within the absorbent structure14.

However it should be understood that in the alternative embodimentshereof, the carrier layer 101 and/or auxiliary 102 can have the same orsimilar properties as the distribution layer 100 a and/or wicking layer100 b and thus be uniform therewith to form the actual absorbentstructure 14. For reasons of clarity the embodiments down below will beexplained so as the distribution layer 100 a and wicking layer 100 b arecomplementary to the carrier layer 101 and the auxiliary layer 102within the absorbent structure 14. Although such distribution layer 100a or wicking layer 100 b is preferably located at the garment facingside of the absorbent polymer material area, it is understood that theorientation of the absorbent structure 14, although not preferred, canalso be re-orientated so as to locate the distribution layer 100 or (forinstance perforated) wicking layer 100 b at the wearer facing side ofthe absorbent polymer material area, while various combinations andvariations are of course also possible. The distribution layer 100 aand/or wicking layer 100 b can for instance also have access means, suchas perforations, holes, channels, openings, fixed or releasable pocketsand the like.

Due to the specific absorbent capacity of the distribution layer 100 a,the liquid around the attachments in between the pockets 130 will bedrawn up into the distribution layer 100 a and will spread outthroughout the rest of the distribution layer 100 a. In a preferredembodiment of the invention, the liquid wetting of the distributionlayer 100 a will therefore also contact the lower side of the absorbentpolymer material area possibly fully or partially closed off by theupper gel-formation and/or -blocking. The absorbent material held in thecompartments 130 will thus advantageously also be contacted from thelower side by redirecting the liquid from the upper side through thedistribution layer 100 b into the absorbent material 110, such asabsorbent particulate polymer material.

Due to the specific distribution capacity of the wicking layer 100 b,the liquid which comes in contact with the substantiallyliquid-impermeable wicking layer 100 b will readily spread out over saidsurface to also contact the absorbent materials 110 located at theadjacent and/or lower surface of the absorbent polymer material area,being the side opposite the major surface side where the liquid wasfirst deposited. The distribution, transport and absorption of theliquid is thus greatly improved and this speedy distribution will helpto avoid large amounts of unbound quantities of liquid within helping toprevent absorbent article failure and high rewet values. Providing anadditional and more direct co-extensive wicking, dispersion andtransportation of liquid to the still more absorbent underused pocketsand compartments of the absorbent structure increases effectiveness andefficiency of the available absorbent materials 110. The presence ofunbound liquid droplets leading to leakages, high rewet values anddiscomfort are thereby minimized.

This distribution layer 100 a has preferably an absorbing capacity of atleast about 1, 2, 3, 4 or 5 g/m², preferably about 10 g/m², morepreferably about 20 g/m², more preferably at least about 35 g/m², mostpreferably at least about 50 g/m², or 100 g/m². Preferably thedistribution layer 100 b is presented in the form of a substantiallycontinuous sheet of cellulosic fibers, such as a nonwoven or a sheet ofpaper or tissue. In a preferred embodiment, it has a basis weight rangewhere the low limit of the range is about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10g/m² per ply, about 13 g/m² per ply, or about 15 g/m² per ply. The highlimit of the basis weight range is about 150 g/m² per ply, 100 g/m² perply, about 40 g/m² per ply, or about 25 g/m² per ply. Suitable wickinglayer 100 b are for instance coated polyethylene or polypropylene films,with a total thickness of such film is usually in the range from 5 to1500 μm, preferably from 10 to 500 μm, for instance a beingcorona-treated, hydrophilic, micro-embossed PE film in the 15-22 μmthickness range.

The substantially liquid-impermeable wicking layer 100 b is for instanceprovided by a substantially continuous layer of foil, film, closed foam,plastic or similar substantially liquid-impermeable materials, mediaand/or layers. The effect of providing the substantiallyliquid-impermeable wicking layer 100 b in the form of a substantiallycontinuous layer of film or foil is that a substantially imperviousbarrier is provided. The provision of a film or foil is advantageouscompared to the use of a pervious layer, such as for instance anon-woven material, as in contrast to such non-woven material the filmor foil is not comprised of fibers. Hence, it is not possible thatfibers are torn upon exertion of a force onto the film or foil, forinstance during movement and/or liquid uptake process (e.g. swelling andexpansion of the absorbent material such as super absorbent polymers).Opposed to non-woven materials, such wicking layer 100 b does notcontain unintentional open spaces and cavities in which unboundquantities of liquid may be stored, thus not leading to an increasedrisks of leakages and augmented rewet with reduced comfort and fit.

In a preferred embodiment the carrier layer 101, auxiliary layer 102,distribution layer 100 a and/or wicking layer 100 b can be fully orpartially hydrophilic or hydrophobic. In a more preferred embodiment,they are provided with a hydrophilic or hydrophobic coating.Combinations thereof are hereby also encompassed. The effect ofproviding such layers with coatings is that the properties of the layercan be modified according to the intended use. For instance, syntheticmaterials that are inherently hydrophobic such as polyethylene (PE) orpolypropylene (PP) can for instance be provided with a coating layersuch that the resulting material has a contact angle of less than 50°,preferably less than 35°, more preferably less than 25°, still morepreferably less than 20°, most preferably less than 15°, for a waterdroplet lying thereon. For instance, materials that are inherentlyhydrophilic can be provided with a hydrophobic coating layer such thatthe resulting material shows hydrophobic properties. This may beadvantage in the fact that a cheap base layer, itself not displaying thedesired property can be adjusted on at least one of its sides to displaythe desired property, thereby providing cost savings. The coating can beapplied by a commonly used suitable process, for example with a slotcoater, or by a spray process. It is particularly preferable to applythe coating by the reverse gravure-roll process, which can apply anextremely homogeneous coating with application weights of from 0.5 to5.0 g/m². The thickness of the coating on the finished film ispreferably from 3 to 1000 nm, in particular from 30 to 200 nm. Obviouslysuch coating can also be applied continuously, substantiallycontinuously, partially or at discreet locations possibly showingmultiple flow enhancing patterns and/or shapes depending on the desiredend product and features.

The distribution layer 100 a and/or wicking layer 100 b used may differin basis weight, thickness, composition or other properties. If providedas multiple plies, they can be passively bound or joined, or a certainamount of adhesive or other attachment means could be added to provideadditional adhesion to portions of the component plies. For example,needling, embossing, or other thermal or mechanical bonding means couldalso be used to actively bond the substantially continuous layer nearsome or all of the edges of the sheet, thereby providing increasedresistance to undesired delaminating of the component plies. Joining mayalso be done by ultrasonic bonding or autogenous bonding, or otherbonding methods known in the art. For example, if the edges of the plyor layers are coextensive with the edges of the outer plies, adhesivebonding and heat sealing adhesive may not provide active bonding,depending on the adhesive used and the surface energy characteristics ofthe ply. In this case, mechanical bonding may be more desirable, forexample by mechanical bonding at a mechanical bonding station afterformation of the multiple plies. Depending on the structural andfunctional requirements the bonding parameters may be adjusted so as toobtain the most suitable dry and wet strength values. If desired,multiple plies of the substantially continuous layer may be joined andembossed. If desired, the plies may be joined together usingknob-to-knob or know-to-flat surface embossing as is known in the art.Alternatively, the multiple plies may be embossed using nestedembossing. The substantially continuous layer may manifest variousphysical characteristics.

The distribution layer 100 a preferably has an absorbency ranging fromabout 0.1 g to 3 g water per g of distribution layer, preferably fromabout 3 to 7 g, more preferably from about 7 to 10 g and preferably theabsorbency is higher than about 10 g water per g of distribution layer100 a. The distribution layer 100 a typically has an absorbent capacityof at least about 5-10 g/m², preferably at least about 30 g/m², morepreferably at least about 50 g/m², more preferably at least about 75g/cm², preferably at least about 100 g/cm² or 150 g/cm². Preferablydistribution layer 100 a is presented in the form of a substantiallycontinuous sheet of cellulosic fiber, such as a sheet of paper, tissueor a drylaid, airlaid or wetiaid material.

Despite the high absorbency and distribution capacities of thesubstantially continuous layer, the bulkiness of said layer isabsolutely and relatively limited, for instance in comparison withabsorbent articles and absorbent structures from the art allowing theenvisaged thinner, more flexible and comfortable structures.

For the present invention, the substantially continuous layers can havea basis weight ranging from about 5 g/m² to about 150 g/m². Preferably,the substantially continuous layer can have a basis weight ranging fromabout 13 g/m² to about 23 g/m². More preferably, the substantiallycontinuous layer can have a basis weight of about 16-18 g/m². Thesubstantially continuous layers preferably have sufficient strength toperform their intended tasks. Preferably, the substantially continuouslayer maintains its integrity when partially or fully wetted, so thatthe distribution of liquids to and the immobilization of the absorbentmaterials may be accomplished. The distribution layer preferably has awet burst strength ranging from a lower limit of about 50-75 g andpreferably about 200 g, to an upper limit of about 800 g, morepreferably about 600 g, and most preferably about 400 g. This isadvantageous as it provides the layer with a good combination ofabsorbency and wet strength. The substantially continuous layer can becreped, uncreped, or wet micro-contracted tissue webs. The substantiallycontinuous layer may be nonwoven, paper or tissue consisting essentiallyof cellulosic papermaking fibers. Optionally, the substantiallycontinuous layer may be foreshortened, and/or contain synthetic fibers.In a preferred embodiment of the absorbent article according to theinvention, the bonds, joints and connections from the distribution layer100 a are not permanent so that the bonds may partially break, detachand/or disintegrate during wetting.

In a preferred embodiment of the invention, portions of the carrierlayer 101 and/or auxiliary layer 102 bond or join to portions of thedistribution layer 100 a; the distribution layer 100 a together with oneor more layers from the absorbent structure 14 cavities for theimmobilization of the absorbent material, preferably absorbentparticulate polymer material. The bonding strength should suffice therequired parameters of the absorbent structure and will amongst othersdepend on the product size, shape, category and required duration of theusage and performance.

The pockets 130 can have a regular shape, irregular shape or combinationthereof. Preferred shapes of the pockets 130 are circular, elliptic orsquare with a diameter, radius or side larger than about 0.1 mm, 0.2 mm,0.3 mm, 0.4 mm, 0.5 mm, more preferably larger than about 0.75 mm andsmaller than about 60 mm, more preferably larger than about 1.0 mm andsmaller than about 40 mm, more preferably lager than about 2.0 mm andsmaller than about 20 mm and most preferably larger than about 3.0 mmand smaller than about 15 mm. The absorbent material 110 does notnecessarily fill the pockets 130 entirely as it might be advantageous toleave some void space adjacent the absorbent material 110 in the pockets130 or leave some pockets 130 partially or completely empty. Theinventor has found that in particular rectangular shaped pockets 130with a side of about 10 mm are particularly advantageous to be used asbuilding blocks for the final compartment sizes within the wetted andreleased absorbent structure 14, as they are easier to manufacture athigh production speed while still allowing meticulous controlling of theprescribed bonding strength of the primary and secondary attachments.

Preferably the distribution of absorbent polymer material is profiledand most preferably profiled in the longitudinal direction. Hence, alongthe longitudinal axis of the absorbent structure, which is normallycoincident with the longitudinal axis of the absorbent article, forexample of the baby diaper, the basis weight of the absorbent polymermaterial will change. Preferably the basis weight of absorbent polymermaterial in at least one freely selected first square measuring 1 cm×1cm is at least about 10%, or 20%, or 30%, 40%, 50% up to more than 100%higher than the basis weight of absorbent polymer material in at leastone freely selected second square measuring 1 cm×1 cm. Preferably thecriterion is met if the first and the second square are centred aboutthe longitudinal axis.

The primary attachments 111 have to substantially resist the frictionsand strain during normal use of the absorbent structure 14 and theforces resulting from the expanding and swelling absorbent material 110caused by the liquid uptake. Since the bonding strength ofwater-sensitive attachment means would be very hard to control duringusage conditions, they are preferably not used within an absorbentstructure 14 according to the present invention. Preferably the dryand/or wet separation force necessary to release the primary attachmentgrids in between the carrier layer 101 and auxiliary layer 102 will behigher than about 0.05 N/cm or about 0.75 N/cm, more preferably higherthan about 0.1, N/cm, 0.2 N/cm or 0.3 N/cm, even more preferably higherthan about 1.0 N/cm, 1.5 N/cm, 2.5 N/cm and most preferably higher thanabout 3-5 N/cm. The attachment grids and patterns can consist of varioussub-regions, corresponding to different separation forces.

As can be seen from FIGS. 4 and 5, the absorbent material pattern formedin between attachments can be random or regular, substantiallycontinuously connected or isolated, fully-covering or partially coveringand/or any other suitable combination. Preferably the absorbent materialregions consists of several clusters of absorbent material 110,surrounded by areas where substantially no absorbent material 110 ispresent, which can act as additional distribution and transport channelsfacilitating the flow of liquid away from the point of insult andtowards available clusters of absorbent material 110. Weightdistribution of absorbent material 110 over the absorbent structure 14can be regular across the major surface or can profiled, i.e. the basisweight of the absorbent material 110 may change depending on itsposition in the absorbent structure 14, for instance very desirable foruse in diaper and pants cores where one would like to concentrateabsolute and/or relative more absorbent material 110 near the point ofliquid insult. Suitable materials such as for instance highly permeableSAP are offered by Evonik, BASF and Nippon Shokubai. Although preferablythe absorbent polymer material form up to 100% of the absorbent material110 it can also be used in combination with other materials such as forinstance cellulose fibres or fluff pulp, however preferably the amountof fibrous materials would not make up more than about zero to 40 weightpercent. Fully cellulose free structures benefit maximal of thisinvention.

The total absorbency and swelling capacity of an absorbent polymermaterials are controlled by the type and degree of cross-linkers used tomake the hydrogel. Low density cross-linked SAP generally has a higherabsorbent capacity and thus typically is able to swell to a relativelylarger degree. These types of SAP also have a softer and more sticky gelformation. High density cross-linked SAP generally exhibits lowerabsorbent capacity and swell to a relative lower degree, but the gel'sstrength is firmer and can maintain particle shape even under modestpressure. Absorbent polymer material are commonly made from thepolymerization of acrylic acid blended with sodium hydroxide in thepresence of an initiator to form a poly-acrylic acid sodium salt(sometimes referred to as sodium polyacrylate). This polymer is the mostcommon type of SAP made in the world today. Other materials are alsoused to make a SAP, such as polyacrylamide copolymer, ethylene maleicanhydride copolymer, cross-linked carboxymethylcellulose, polyvinylalcohol copolymers, cross-linked polyethylene oxide, and starch graftedcopolymer of polyacrylonitrile to name a few. The latter is one of theolder SAP forms created.

All these SAP technologies have been common in the absorbent structureindustries for many years and are well-known by the persons skilled inthe art. Generally, SAP manufacturers can vary several processparameters and finishing specifications such as cross-linking level andparticle size and offer the absorbent article designers a wide choice ofabsorbent polymer material products ranging from SAP with low swellingcapacity to high swelling capacity, and from slow swelling behavior tofast swelling behavior. By making the appropriate choice, one can designabsorbent structures with a combination of such different SAP concepts,where preferably the fast swelling SAP and/or SAP with high swellingcapacity would be used in the areas which would have to act as heightsor embankments, while preferably the slow swelling SAP and/or SAP withlow swelling capacity would be used in the areas which would have to actas depressions or canals.

In an alternative embodiment of this invention, one can use higheramounts of SAP in certain areas, while other areas would be free fromSAP or have relative limited amounts of SAP so that, when wetted, theareas with relative higher amounts of SAP would swell to form heightswhile those without or with relatively limited amounts of SAP would formthe depressions.

The breaking of the secondary attachments 115 allows the carrier layer101 and/or auxiliary layer 102 to deform, stretch and change shape. As aresult, the minimal volume pockets 130 are able to expand to anintermediate volumes and finally to maximum volume compartments so as toaccommodate the extra volume resulting from the highly expandableabsorbent material 110. Thus, as seen in FIG. 6, an absorbent structure14 with expandable pockets 130 with additional activated free swellvolume is created, allowing the absorbent material 110 to be moreeffectively and efficiently used and reducing the risk of bursting ofone or more sandwiching layers. The extra volume created by theexpanding pockets can for instance be about 1% to 5% of the originalvolume. Preferably it is higher than about 5% to 25%, more preferablyhigher than about 25% to 50%, most preferably higher than about 50% or100% of the original volume. In an alternative embodiment, the absorbentstructure 14 consists of multilayered sandwich structures where on thefirst sandwich structure of carrier layer 101—absorbent material110—auxiliary layer 102, additional layers of absorbent material and/orcomplementary layers can be added. Such structures can provide goodliquid absorption whilst retaining product integrity, in dry and wetstate.

FIGS. 7, 8 and 9 show embodiments according to the invention wheresecondary attachment 115 consist of weaker secondary attachments 115′and stronger secondary attachments 115″ where weaker secondaryattachments 115′ loosen faster than the stronger secondary attachments115″. The different functionalities in between the primary attachments111 and secondary attachments 115 in combination with the bondingstrength differentiation in between weaker secondary attachments 115′and stronger secondary attachments 115″ allows the design of anabsorbent structure 14 with a predetermined, controlled and/or phasedvolume-expansion of the absorbent structure for ultimate fluidmanagement.

In a more preferred embodiment, the absorbent structure 14 consists ofweaker secondary attachments 115′ at the periphery of the absorbentstructure 14 allowing for primary and easy expansion of the absorbentmaterial 110 adjacent the longitudinal and/or end edges of the absorbentstructure 14, thereby creating containment or anti-leakage barrierswithin the absorbent structure 14. Such a particular internalincorporated barrier construction has great pre-usage, usage andpost-usage advantages for the construction of disposable absorbenthygiene articles such as garments, diapers or pants. As shown in FIGS.7, 8 and 9, the weaker secondary attachment 115′ loosen to form firstbarriers or embankments 150, whereas the stronger secondary attachments115″ form the only later arising secondary barriers or embankments 151.The substantially wet-resistant permanent primary grids form canals 152in between the first embankments 150 and/or the secondary embankments151. Due to the time difference between the formation of the firstembankments 150 and the respective secondary embankments 151, the firstembankments 150 will contain the liquid inside the product, where it canbe distributed via the canals 152 and it will further be stored in andcontained by secondary embankments 151. Obviously combinations andvariants are possible.

In a preferred embodiment, one can for instance create embankments insuch a way to obtain a pocket being an elongated or rounded depression,substantially surrounded by embankments. Such embankments can be loweredor interrupted to create one or more in- or outlets. The void spaceinside the pocket can especially be used to store liquids, solids and/orliquids of high viscosity. In baby diaper or adult incontinenceproducts, such additional embankments can act as a cushion, providingcomfort, keeping skin away from stool and preventing stool to be pushedout of the absorbent article when the wearer exerts pressure, e.g. bysitting, on the product. Various shapes, sizes, locations andcombinations can be envisaged. In a more preferred embodiment of thisinvention, one can create a stool containing pocket since it is knownthat infant stool can be very ‘liquid-like’.

Human feces (or human faeces), also known as stools, is the wasteproduct of the human digestive system and varies significantly inappearance, depending on the state of the whole digestive system,influenced and found by diet and health. Normally stools are semisolid,with a mucus coating. The Bristol Stool Chart or Bristol Stool Scale isa medical aid designed to classify the form of human feces into sevencategories. Sometimes referred to in the UK as the “Meyers Scale,” itwas developed by K. W. Heaton at the University of Bristol and was firstpublished in the Scandinavian Journal of Gastroenterology in 1997. Theform of the stool depends on the time it spends in the colon.

The seven types of stool are:

1. Separate hard lumps, like nuts (hard to pass).2. Sausage-shaped but lumpy.3. Like a sausage but with cracks on its surface.4. Like a sausage or snake, smooth and soft.5. Soft blobs with clear cut edges (passed easily).6. Fluffy pieces with ragged edges, a mushy stool.7. Watery stool, entirely liquid.

Types 1 and 2 indicate constipation, with 3 and 4 being the “idealstools” especially the latter, as they are the easiest to pass, and 5-7being further tending towards diarrhea or urgency. Stool from smallchildren, and especially younger babies, can often be classified in type5, 6 or 7 and may be referred to as ‘liquid stool’.

Due to its high viscosity, the liquid stool does not significantly getabsorbed through the topsheet of the absorbent article, and often givesrise to a leakage. Leakage of stool from an absorption article is evenless appreciated than urine leakage, as the former provides even moreinconvenience to the wearer and caretaker, and provides more problemsfor health and hygiene. By creating the superficial liquid managementsystem such as for instance a stool pocket, one can create a void spacewhich can be filled with stool. Contained by the embankments, the stoolwill substantially remain in place. In order for a stool pocket toperform optimally, the depressions should be at least 5%, preferably10%, more preferably 15% or most preferably at least 20% lower than theheights in the rear section of the product.

In alternative embodiment, at least one of the carrier layers 101 orauxiliary layer 102 is made out of an elastic or stretchable material,allowing for at least a first volume expansion before the graduallyincreasing expansion force of the wetting and swelling absorbentmaterials 110 accommodates the eventual breaking of the wet secondaryattachments 118.

With reference to FIG. 10 A-B the primary attachments 111 from theabsorbent structure 14 correspond with a predefined primary bondinggrids 113, whereas the secondary attachments 115 from the absorbentstructure 14 correspond with a secondary bonding pattern 117. These gridand pattern shapes are developed in light of the desired structural andfunctional features. Obviously these grids and patterns merely act asillustrations and examples as various combinations, shapes and sizes areof course possible in relation to desirable absorbent structures.Referring to FIG. 10A, the lines of these patterns may be disposedregular or irregular, continuous or discontinuous, coextensive with theentire surface of the absorbent structure or only part thereof and anycombination and/or derivations thereof. These lines may be aligned withthe longitudinal, transversal or diagonal axis of the absorbentstructure 14 or alternatively any angle in respect of such axis. It hasbeen found that, that a continuous disposition of these lines throughoutthe absorbent structure 14 creates additional channels and ducts whichhelp the fluid transport from the point of liquid contact to the rest ofthe absorbent structure via mass flow allowing better and more spreadout immediate liquid management via capillary flow locally. Care howevershould be taken not to allow channelling of liquid to the very side ofthe absorbent structures to avoid leakages upon time of insult,preferably they will thus guide the liquid to the entire surface of theabsorbent structure with the exception of the outer edges thereof.Another preferred pattern for grids and patterns comprises polygons, forexample pentagons and sexangles or a combination thereof. Also irregularpatterns are possible. In essence those grids and patterns are preferredwhich allow optimal packaging of absorbent particulate material in drysmaller pockets 130 while allowing ideal and maximum volume expansion tobigger compartment in wet state taking in mind the thin and flexibleabsorbent structures are envisaged. Too much loss of pocket and/orcompartment volume in light of primary and secondary attachment gridsand patterns in respective dry and wet stat is preferably avoided.

Referring to FIG. 10B, exemplary absorbent structures are shown withintact primary bonding grids 113 and released secondary pattern 117leading to the bigger and fewer compartments as opposed to the pluralityof smaller pockets 130 formed by the intact primary attachments 111 andsecondary attachments 115 (FIG. 10A).

The invention provides use of an absorbent structure according to anembodiment of the invention in an absorbent product, selected from thelist of coffee pads, disposable body warmers, sheet formed detergentarticle, filter material, insulation material, make-up pads, anti-septicwads, feminine hygiene garments, baby diapers, baby pants, adultincontinence garments, preferably said absorbent article is a femininehygiene garment, baby diaper, baby pants or adult incontinence garment.The construction of such commercially available products is well-knowfrom the art.

The absorbent structure claimed according to the present invention isthin and flexible, and thus has a low flexure-resistance. Theflexure-resistance of the absorbent structures is measured by the PeakBending Stiffness as determined by the test which is modelled after theASTM D 4032-82 Circular Bend Procedure, the procedure being considerablymodified and performed as described in EP0336578B1. In a preferredembodiment of the absorbent article of the invention, the absorbentstructure has a flexure-resistance of less than 500.0 grams, morepreferably less than about 250.0-350.0 grams, and still more preferablyless than about 175.0 grams and most preferably less than about 130.0 or100.0 grams. Thus, the absorbent structure of the present invention ishighly flexible and conforms very well to the various shapes of theurogenital region. Use of an absorbent structure with this low aflexure-resistance has for effect that an easily flexible absorbentarticles can be provided. This feature is advantageous as such astructure will easily ply and allow the structure to follow a bodyshape, and thus wearer fit and comfort.

The absorbent structure claimed according to the present invention hassuperior immobilisation characteristic in dry and wet state and theminimum wet immobilisation values as measured by the shaker test weightretention as determined by the Wet Immobilisation test as described inUS Patent Application 20070167928 are very favourable. In a preferredembodiment of the absorbent structure of the invention, the absorbentstructure has a wet immobilization of more than 60 wt %, preferably morethan 70 wt %, more preferably more than 80 wt %, and most preferablymore than 90 wt %. Such absorbent structure has an increased loadingcapacity and an improved absorption capacity.

With reference to FIG. 11, a method and apparatus is illustrated forforming a composite structure 700 according to the present invention,having a plurality of discrete particulate material clusters 703 whichare preferably discretely distributed and deposited on a carrier layer101 and contain selected quantities of particulate material 703. Therepresentatively shown apparatus includes a particulate materialsupplying means 200 for providing absorbent materials 110 towardscarrier layer 101. A web supplying means 400 and web transport means 402provides a carrier layer 101 and a support means 600 via guiding means601 and 602 moves the carrier layer 101 adjacent a depositing means,preferably provided in the form of a substantially endless rotating drum100. A material supply means 200 direct absorbent material 110 by way ofa dosing system 204 and a feeding tube 205 towards the a proximalopening 206. Optional brushing means 208 help to ‘right-fill’ theclustering means 250. The depositing means 206 preferably havingclustering means 250 with a pattern of perforations arranged to form andprovide a desired depositing pattern of particulate material clusters703 onto the carrier layer 101. The support means 600 is preferably insubstantial contact with the support surface 412 of the carrier layer101. The support means 600 preferably ensures a close enough connectionin between the deposit surface 411 of the carrier layer 101 andclustering means 250 to prevent unwanted migration of the particulatematerials 110 from the carrier deposit zones to the carrierinter-deposit zones. Preferably also a position means is provide whichcan be unitary with the support means 600, and which stabilizes,positions and/or repositions any blurring in the printing pattern ofparticulate material clusters 703 towards an exact pocketing patternprior to immobilisation. A covering means 500 and web transporting 502provides an auxiliary layer 102, such as for instance a liquid-permeablefibrous web such as a non-woven, paper, tissue, woven, fabric, web,perforated film or foil. Alternatively the auxiliary layer 101 can alsorepresent a homogenous and/or heterogeneous layer of glue, adhesive,binders, resins, thermoplastic material and the like, capable ofsandwiching the particulate materials clusters 703 between the carrierlayer and auxiliary layer to form a composite structure 700, such as forinstance an absorbent structure 14. This relative expensive, technicallychallenging and environmentally burdensome alternative embodimentaccording to the invention is however not preferred above the non-woven,paper or tissue like layer for instance. A much preferred attachmentprocess according to a preferred embodiment of the present inventioncomprises an airflow generated by blowing zones having an overpressurein comparison to standard process pressure and/or by suction zoneshaving an under-pressure in comparison to standard process pressure.Alternatively, a combination of blowing and/or suction holes is used forairflow. Ultrasonic means 800 and adhesive applicator means 900 and/or901 may also be provided.

An exemplary absorbent article is disposable baby diaper.

FIG. 12 is a top plan view of a diaper 10 as a preferred embodiment ofan absorbent article including an absorbent structure according to thepresent invention. It should be understood, however, that the presentinvention is also applicable to other absorbent articles such asfeminine hygiene garments, baby pants, adult incontinent garments andthe like.

The absorbent article is shown in its flat out, un-contracted state withthe wearer side facing the viewer. Portions of the absorbent article arecut away to more clearly show the underlying structure of the diaper 10including the absorbent elements and absorbent components. The chassis12 of the diaper 10 in FIG. 12 comprises the main body of the diaper 10.The chassis 12 comprises an outer covering including a liquid pervioustop sheet 18 and/or a liquid impervious back sheet 20. The chassis 12may include a portion of an absorbent structure 14 encased between thetop sheet 18 and the back sheet 20. The chassis 12 may also include mostor all of the absorbent structure 14 encased between the top sheet 18and the back sheet 20. The chassis 12 preferably further includes sidepanels or ears 22, elasticized leg cuffs 24 and elastic waist features26, the leg cuffs 24 and the elastic waist feature 26 each typicallycomprise elastic members 28. One end portion of the diaper 10 isconfigured as a front waist region 30 of the diaper 10. The opposite endportion is configured as a back waist region 32 of the diaper 10. Anintermediate portion of the diaper 10 is configured as a crotch region34, which extends longitudinally between the first and second waistregions 30 and 32. The waist regions 30 and 32 may include elasticelements such that they gather about the waist of the wearer to provideimproved fit and containment (e.g. elastic waist feature 26). The crotchregion 34 is that portion of the diaper 10 which, when the diaper 10 isworn, is generally positioned between the wearer's legs. The diaper 10is depicted with its longitudinal axis 36 and its transverse axis 38.The periphery of the diaper 10 is defined by the outer edges of thediaper 10 in which the longitudinal edges 42 run generally parallel tothe longitudinal axis 36 of the diaper 10 and the end edges 44 runbetween the longitudinal edges 42 generally parallel to the transverseaxis 38 of the diaper. The chassis 12 also comprises a fastening system,which may include at least one fastening or securing member 46 and atleast one landing zone 48. The various components within the diaper 10may be bound, joined or secured by any method know in the art, forexample by adhesives in uniform continuous layers, patterned layers orarrays of separate lines, spirals or spots. The top sheet 18, the backsheet 20, the absorbent structure 14 and other components may beassembled in a variety of well-known configurations and are well knownin the art.

The back sheet 20 covers the absorbent structure 14 and preferablyextends beyond the absorbent structure 14 toward the longitudinal edges42 and end edges 44 of the diaper 10 and may be joined with the topsheet 18. The back sheet 20 prevents the bodily exudates absorbed by theabsorbent structure 14 and contained within the diaper 10 from soilingother external articles that may contact the wearer, such as bed sheetsand undergarments. In preferred embodiments, the back sheet 20 issubstantially impervious to bodily exudates and comprises a laminate ofa nonwoven and a thin plastic film such as a thermoplastic film. Theback sheet 20 may comprise breathable materials that permit vapour toescape from the diaper 10 while still preventing bodily exudates frompassing through the back sheet 20. It may be semi-rigid, non-elastic andcan be made fully or partially elasticized and include backing. The backsheets 20 may be assembled in a variety of well-known configurations andare well known in the art.

The diaper 10 comprises a top sheet 18 that is preferably soft,compliant, exhibits good strikethroughs and has a reduced tendency torewet from the liquid absorbent material. The top sheet 18 is placed inclose proximity to the skin of the wearer when the diaper 10 is worn. Inthis way, such top sheet 18 permits bodily exudates to rapidly penetrateit so as to flow toward the absorbent structure 14 more quickly, butpreferably not allowing such bodily exudates to flow back through thetop sheet 18. The top sheet 18 may be constructed from any one of a widerange of liquid and vapour permeable, preferably hydrophilic, materials.The upper and lower surface of the top sheet 18 may be treateddifferently and may for instance include a surfactant on the uppersurface so as to facilitate liquid transfer there through, especially ata central zone or area of the top sheet 18 located over the absorbentstructure 10, and for instance include a hydrophobic agent on the lowersurface to minimize the liquid contained within the absorbent core fromcontact wetting the top sheet 18 thereby reducing rewet values. The topsheet 18 may also be coated with a substance having rash preventing orrash reducing properties (e.g. aloe vera). The top sheet 18 coverssubstantially the entire wearer facing area of the diaper 10, includingsubstantially all of the front waist region 30, back waist region 32,and crotch region 34. Further, the side panels 22 and/or waist featurelayers of the inner region may be formed from the same single top sheetmaterial and, thus, may be referred to as being unitary with the topsheet 18 in forming longitudinal and lateral extensions of the top sheet18 material. Alternatively, the top sheet 18 may be formed from multipledifferent materials which vary across the width of the top sheet 18.Such a multiple piece design allows for creation of preferred propertiesand different zones of the top sheet 18. The top sheet 18 be semi-rigid,non-elastic and can be made fully or partially elasticized. The topsheet 18 may be assembled in a variety of well-known configurations andare well known in the art.

The absorbent structure 14 in FIG. 12 generally is disposed between thetop sheet 18 and the back sheet 20. The absorbent structure 14 maycomprise any absorbent material 110 that is generally compressible,conformable, non-irritating to the wearer's skin, and capable ofabsorbing and retaining bodily exudates. The absorbent structure 14 maycomprise a wide variety of liquid absorbent materials 110 commonly usedin absorbent articles such as fluff pulp, which is generally referred toas airlaid. Examples of other suitable absorbent materials includecreped cellulose wadding; melt blown polymers; chemically stiffened,modified or cross-linked cellulosic fibres; tissue, including tissuewraps and tissue laminates; absorbent foams; absorbent sponges;absorbent polymer materials; absorbent gelling materials; or any otherknown absorbent materials or combinations of materials. The absorbentstructure 14 may further comprise minor amounts (typically less than10%) of non-liquid absorbent materials, such as adhesives, binders,plastics, waxes, oils and the like. The absorbent structure 14 accordingto various embodiments of the invention may be configured to extendsubstantially the full length and/or width of the diaper 10. However,alternatively the absorbent structure 14 according to the invention isnot coextensive with the entire diaper 10 and is limited to certainregions of the diaper 10 such as for instance the crotch region 34. Invarious embodiments, the absorbent structure 14 extends to the edges ofthe diaper 10 and the absorbent material 110 is concentrated in thecrotch region 34 or another target zone of the diaper 10. In stillanother embodiment, the particles can be a combination of absorbentmaterial 110, preferably comprising absorbent polymer material, and skincare particles such as ion exchange resins, deodorant, anti-microbialagents, binder particles, or other beneficial particles.

The diaper 10 may also utilize a pair of containment walls or cuffs 24.Each cuff 24 is a longitudinally extending wall structure preferablypositioned on each side of the absorbent structure 14 and spacedlaterally from the longitudinal axis 36. The longitudinal ends of thecuffs 24 may be attached or joined, for example, to the top sheet 18 inthe front and rear waist regions 30 and 32. Preferably, the ends of thecuffs 24 are tacked down inwardly and attached, for example, by adhesiveor sonic bonding to the lower structure. Such a construction effectivelybiases the cuffs 24 inwardly and is generally considered to cause thecuffs 24 to exhibit improved leakage prevention properties. Preferably,the cuffs 24 are equipped with elastic members 28, which extend along asubstantial length of the cuffs 24. In a common application, the elasticmembers 28 are placed within the cuffs 24, preferably at the top of thecuff 24 while in a stretched condition and then glued or sonic bonded tothe cuff 24 at least at their ends. When released or otherwise allowedrelaxing, the elastic members 28 retract inwardly. When the diaper 10 isworn, the elastic members 28 function to contract the cuffs 24 about thebuttocks and the thighs of the wearer in a manner, which forms a sealsbetween the diaper 10, the buttocks and the thighs. The cuffs 24 may beassembled in a variety of well-known configurations and are well knownin the art.

The diaper 10 may also employ additional layers known in the artincluding an acquisition layer or surge layer, preferably situatedbetween the top sheet and the absorbent core and highloft and/orcoverstock layers. This serves to slow down the flow so that the liquidhas adequate time to be absorbed by the absorbent core.

In order to keep the diaper 10 in place about the wearer, preferably atleast a portion of the back waist region 32 is attached by fastening orsecuring members 46 to at least a portion of the front waist region 30,preferably to form leg openings and an absorbent article waist.Fastening or securing members 46 carry the tensile load around theabsorbent article waist and compliment the elastic members 28 byproviding a quasi-seal between the wearer, the elastic waist feature 26and cuffs 24, so that bodily exudates are contained within the diaper 10which are then absorbed.

In other words, so that it does not leak through gaps between the wearerand the edge of the diaper 10. The fastening or securing members 46 mayfor instance be adhesive, mechanical fasteners, hook and loop features,conceivable strings and/or combinations thereof, i.e., anything thatwill secure one end of the diaper 10 to the longitudinally opposite endof the diaper 10. The fastening or securing members 46 may also beco-adhesive such that they adhere to each other but not other materials.The fastening or securing members 46 and any component thereof mayinclude any material suitable for such a use, including but not limitedto plastics, films, foams, non-woven webs, woven webs, paper, laminates,fibre reinforced plastics and the like, or combinations thereof. It maybe preferable that the materials making up the fastening or securingmembers 46 are flexible, extensible and/or elastic, allowing them tobetter conform to the shape and movements of the body and thus, reducesthe likelihood that the fastening system will irritate or injure thewearer's skin. Preferably, the diaper 10 is affixed to the wearer bytape fasteners which are permanently affixed to the back sheet 20. Tapefasteners are contacted with the transversely opposite side panel orears 22 attached or joined and extending from the back sheet 20, wherethey remain affixed due to the binding compound applied to thefasteners. Alternatively, the absorbent article may be pants and thelike. In this configuration, the absorbent article may or may not havetape fasteners. Specific disposability tapes may however also beprovided on such absorbent articles. All fastening and securing elements46 may be assembled in a variety of well-known configurations and arewell known in the art.

The waist regions 30 and 32 each comprise a central region and a pair ofside panels or ears 22 which typically comprise the outer lateralportions of the waist regions. These side panels 22 may be unitary withthe chassis 12 and/or back sheet 20 or may be attached or joined theretoby any means know in the art. In a preferred embodiment of the presentinvention, the side panels 22 positioned in the back waist region 32 areflexible, extensible and/or elastic in at least the lateral direction(i.e., elasticized side panels), in another embodiment the side panels22 are non-elastic, semi-rigid, rigid and/or stiff. These variety ofside panels 22 are known in the art.

Furthermore waistbands 26 employing elastic members can be positionedalong the transverse portion of the diaper 10 so that when worn, thewaistbands 26 are positioned along the waist of the wearer. Generally,the waistband 26 preferably creates a seal against the waist so thatbodily exudates do not leak from the regions between the elasticwaistband 26 and the waist of the wearer. Although the bodily exudatesare primarily absorbed by the absorbent materials within the diaper 10,the seal is important considering the assault of liquid by the wearermay overwhelm the absorption rate capacity of the absorbent structure14. Hence, the waistbands 26 contain the liquid while it is beingabsorbed, they are well known in the art.

The absorbent article such as a diaper 10 may also include such otherfeatures, components and elements as are known in the art includingfront and rear ear panels, waist cap features, elastics and the like toprovide better fit, containment and aesthetic characteristics. Thesefeatures may be assembled in a variety of well-known configurations andare well known in the art.

The process for producing preferred absorbent structures in accordancewith the present invention comprises the following steps: A carrierlayer 101 is provided onto which absorbent material 110 is disposed bymethods known in the art. To deposit the absorbent material 110, vacuum,gravity or other forces can be used. Then an auxiliary layer 102 isprovided, covering the absorbent material 110, and primary bondingregions 111 and secondary bonding regions 115 are being provided. Incase one would like to use adhesives or chemical binders, then it mightbe useful to attach these to the carrier layer 101 and/or auxiliarylayer 102 layer prior to bringing the sandwich structure together. Incase one opts for thermo-sealed bonding areas, then the thermo-sealingcan be applied after the sandwich structure components have been broughttogether. It is of course also possible to combine both techniques inthe same absorbent structure.

The process for producing preferred absorbent structures 14 inaccordance with the present invention comprises the following steps: Acarrier layer 101 is provided onto which absorbent material 110 isdisposed by methods known in the art. To deposit the absorbent material110, vacuum, gravity or other forces can be used. Then an auxiliarylayer 102 is provided, covering the absorbent material 110, and primaryattachments 111 and secondary attachments 115 are being provided,preferably via sonic bonding. In case one would like to use adhesives orchemical binders, then it might be useful to attach these to the carrierlayer 101 and/or auxiliary layer 102 layer prior to bringing thesandwich structure together. In case one opts for thermo-sealed or sonicbonding areas, then the thermo-sealing can be applied after the sandwichstructure components have been brought together. It is of course alsopossible to combine both techniques in the same absorbent structure.

1. A substantially cellulose free absorbent structure comprising acarrier layer, an auxiliary layer and an absorbent polymer materialthere between, the carrier layer and auxiliary layer being at leastpartially joined together by attachments made up of substantiallypermanent primary attachment grids and/or substantially temporarysecondary attachment patterns, so as to form a sandwich-like compositestructure containing patterned absorbent particulate polymer materialsprovided in at least some of the unattached regions between the carrierlayer and auxiliary layer forming an absorbent polymer material area,the plurality of smaller-sized pockets made up by at least substantiallytemporary secondary attachments define spaces which immobilize theavailable dry volume absorbent polymer material, the substantiallytemporary secondary attachment being gradually releasable as a result ofexposing the surrounding absorbent polymer material to liquid so asphase in an intermediate volume increase to fewer and medium-sizedcompartments immobilising the partially wetted absorbent polymermaterial, and resulting in still fewer maximum-sized compartmentsimmobilising the wetted absorbent polymer material to obtain continuousfluid management.
 2. An absorbent structure according to claim 1characterized in that its substantially permanent primary attachmentsare provided, in combination with the substantially temporary secondaryattachment to make up the initial small-sized pockets, which remainsubstantially intact.
 3. An absorbent structure according to claim 1,characterized in that the substantially permanent primary attachmentgrid and/or substantially temporary secondary attachment pattern isdistributed over substantially the majority of the surface area of theabsorbent polymer material area.
 4. An absorbent structure according toclaim 1, characterized in that the absorbent structure non-homogeneouslyswells to form a liquid management surface structure due to release ofthe substantially temporary secondary attachments.
 5. An absorbentstructure according to claim 1, characterized in that the absorbentstructure non-homogeneously swells to form a liquid management surfacestructure due to phased swelling of the absorbent polymer material area.6. An absorbent structure according to claim 1, wherein the attachmentsare at least partially formed via a mechanical, thermal, physical,chemical, thermo-mechanical and/or most preferably an ultrasonicprocess.
 7. An absorbent structure according to claim 1, wherein atleast some or all of the substantially permanent primary attachmentsand/or substantially temporary secondary attachments are formed with atleast an adhesive or binder as an attachment medium.
 8. An absorbentstructure according to claim 1, wherein the substantially permanentprimary attachments and/or substantially temporary secondary attachmentshave different locations, sizes and/or shapes.
 9. An absorbent structureaccording claim 1, wherein at least 80% of the absorbent material isabsorbent polymer material.
 10. An absorbent structure according toclaim 1, wherein the absorbent structure has on average within theabsorbent polymer material area at least one pocket per about 0.10 cm²,preferably 1 per about 0.50 cm², preferably 1 per about 1 cm²;preferably 1 per about 2.5 cm², preferably 1 per about 5 cm² and/or atleast 1 compartment per about 5 cm², preferably 1 per about 10 cm²,preferably 1 per about 20 cm², preferably 1 per about 30 cm², preferably1 per about 45 cm²
 11. An absorbent structure according to claim 1,wherein at least some or all of the substantially permanent primaryattachments and/or substantially temporary secondary attachments have anaverage surface size of at least 0.3 mm², preferably at least 0.5 mm²,preferably at least 1.0 mm² and more preferably at least 3.0 mm². 12.Absorbent structure according to claim 1, wherein the absorbentstructure has a flexure-resistance of less than 500.0 grams, morepreferably less than 250.0 grams, and still more preferably less thanabout 175.0 grams and most preferably less than 130.0 grams or 100.0grams.
 13. Absorbent structure according to claim 1, with a wetimmobilization of more than 50 wt %, preferably more than 60 wt %,preferably more than 7 wt %, more preferably more than 80 wt %.
 14. Anabsorbent article comprising an absorbent structure according to claim1, wherein said absorbent article is a feminine hygiene garment, babydiaper, baby pants or adult incontinence garment.
 15. An absorbentarticle according to claim 1, comprising a liquid pervious topsheet, aliquid impervious backsheet and a liquid absorbing absorbent structuresituated in between the liquid pervious topsheet and liquid imperviousbacksheet.
 16. A method for the manufacturing of an absorbent structureaccording to claim 1 which comprises: providing a carrier layer,covering the carrier layer with an absorbent material, covering theabsorbent material with an auxiliary layer which is joinable to thecarrier layer; and in at least one position substantially temporaryand/or substantially permanently attaching the auxiliary layer to thecarrier layer, and by means of at least substantially temporarysecondary attachments defining small-sized pocket wherein dry absorbentmaterial is immobilized, such that by means of gradual release ofsubstantially temporary secondary attachment patterns bigger-sizedintermediate and final compartments are provided, thereby continuouslyimmobilising the absorbent material from dry to wetted state.